CN116735196B - Gearbox reinforced load spectrum test method aiming at bearing damage - Google Patents

Gearbox reinforced load spectrum test method aiming at bearing damage Download PDF

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CN116735196B
CN116735196B CN202311027970.6A CN202311027970A CN116735196B CN 116735196 B CN116735196 B CN 116735196B CN 202311027970 A CN202311027970 A CN 202311027970A CN 116735196 B CN116735196 B CN 116735196B
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gear
torque
bearing
load spectrum
input torque
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CN116735196A (en
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赵培龙
高晓光
孟静
赵洪杰
刘敦宁
苑衍灵
马宏刚
王硕
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Shengrui Transmission Co Ltd
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Shengrui Transmission Co Ltd
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M13/00Testing of machine parts
    • G01M13/02Gearings; Transmission mechanisms
    • G01M13/025Test-benches with rotational drive means and loading means; Load or drive simulation
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation

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  • General Physics & Mathematics (AREA)
  • Testing Of Devices, Machine Parts, Or Other Structures Thereof (AREA)

Abstract

The invention discloses a gearbox reinforced load spectrum test method aiming at bearing damage, which relates to the technical field of gearbox test methods and comprises the following steps: s1, determining a test load spectrum, and counting the input rotation speed, the input torque and the gear time of each gear in the test load spectrum; s2, calculating the bearing damage life of each gear under the test load spectrum; s3, calculating the total damage life of the bearing; s4, determining a gear of the enhanced load spectrum; s5, determining the input rotation speed of the enhanced load spectrum; s6, determining the input torque of the intensified load spectrum; and S7, calculating the time when the damage of the bearing under the reinforced load spectrum is equal to the total damage life of the bearing obtained in the step S3, namely, the test time of the reinforced load spectrum. The invention can only carry out special endurance test for damaged parts, greatly shortens the test period and reduces the test cost.

Description

Gearbox reinforced load spectrum test method aiming at bearing damage
Technical Field
The invention relates to the technical field of gearbox test methods, in particular to a reinforced load spectrum test method for a multi-gear automatic gearbox aiming at bearing damage.
Background
The automatic gearbox is a speed changing device capable of automatically performing automatic gear shifting operation according to the speed of an automobile and the rotation speed of an engine, and the multi-gear automatic gearbox is complex in structure, comprises parts such as a clutch, a bearing, a gear and the like, and is complex in power flow relation of each gear. Therefore, in order to ensure the quality of the automatic gearbox, a static endurance test is required to be carried out on the whole gearbox before the automatic gearbox is marketed, and the static endurance test is used for checking the service lives of all parts of the whole gearbox, so that the test period is long and the cost is high. However, in the static endurance test, one of the parts, such as the bearing, is damaged, and at present, if one part is damaged in the static endurance test, the damaged part needs to be replaced, and after replacement, the static endurance test is performed again, so that the cost is high and the test period is long.
Disclosure of Invention
Aiming at the defects, the invention aims to provide the gearbox reinforcement load spectrum test method aiming at bearing damage, which can only carry out special endurance test on damaged parts, thereby greatly shortening test period and reducing test cost.
In order to achieve the above object, the technical scheme of the present invention is as follows:
a gearbox reinforced load spectrum test method aiming at bearing damage comprises the following steps: s1, determining a test load spectrum, and counting the input rotation speed, the input torque and the gear time of each gear in the test load spectrum; s2, calculating the bearing damage life of each gear under the test load spectrum; s3, calculating the total damage life of the bearing; s4, determining a gear of the enhanced load spectrum; s5, determining the input rotation speed of the enhanced load spectrum; s6, determining the input torque of the intensified load spectrum; and S7, calculating the time when the damage of the bearing under the reinforced load spectrum is equal to the total damage life of the bearing obtained in the step S3, namely, the test time of the reinforced load spectrum.
In the step S2, the rotational speed and torque of the gear of the gearbox under each working condition are calculated according to the input rotational speed and the input torque counted in the step S1, the bearing rotational speed and stress of each gear are calculated according to the rotational speed and the torque of the gear, and the bearing damage life of each gear is calculated according to the bearing rotational speed and the stress of each gear.
In the step S3, according to the fatigue equivalent accumulation theory, the bearing damage lives of the gears calculated in the step S2 are respectively accumulated and summed, so as to calculate the total damage life of the bearing.
In the step S4, according to the transmission principle of the multi-gear gearbox, the stress of the bearing under each gear is calculated, and the gear with the largest bearing stress is determined to be the gear with the reinforced load spectrum.
In the step S5, the maximum value of the engine speed of the rounding vehicle and the rotation speed of the test stand is the input rotation speed of the enhanced load spectrum.
In the step S6, firstly, the input torque is preliminarily determined so that the preliminarily determined input torque is smaller than the bearing capacity of the clutch, then, the safety coefficient of the gear is calculated according to the preliminarily determined input torque, and if the calculated safety coefficient of the gear meets the reliability requirement of the gear, the preliminarily determined input torque is determined as the input torque of the strengthening load spectrum; if the calculated safety coefficient of the gear does not meet the reliability requirement of the gear, the preliminarily determined input torque value is reduced, and then the gear safety coefficient is calculated until the calculated gear safety coefficient meets the reliability requirement of the gear.
The safety coefficient calculation steps of the gear are as follows: calculating the torque of the gear according to the preliminarily determined input torque; calculating the stress of the gear according to the torque of the gear; calculating the contact stress and bending stress of the gear according to the stress of the gear; and calculating the safety coefficient of the gear according to the contact stress and the bending stress of the gear.
The safety coefficient of the gear is larger than 1.2, and the requirement of gear reliability is met.
Wherein the preliminary determination of the input torque is as follows: calculating the torque capacity of the clutch; the torque capacity of the clutch is divided by the transmission ratio of the clutch, and the obtained value is the input torque of the preliminarily determined intensified load spectrum.
Wherein the preliminary determination of the input torque is as follows: giving a numerical value as an input torque predicted value; multiplying the input torque predicted value by the transmission ratio of the clutch to obtain the estimated clutch torque; calculating the torque capacity of the clutch; comparing the estimated clutch torque with the torque capacity of the clutch, and if the estimated clutch torque is smaller than the torque capacity of the clutch, determining a given input torque estimated value as the preliminarily determined input torque; if the estimated clutch torque is larger than the torque capacity of the clutch, the input torque estimated value is reduced, and the steps are repeated until the estimated clutch torque is smaller than the torque capacity of the clutch.
After the technical scheme is adopted, the invention has the beneficial effects that:
the gearbox reinforced load spectrum test method aiming at bearing damage comprises the following steps: s1, determining a test load spectrum, and counting input rotation speed, input torque and gear time under each gear in the test load spectrum; s2, calculating the bearing damage life of each gear under the test load spectrum; s3, calculating the total damage life of the bearing; s4, determining a gear of the enhanced load spectrum; s5, determining the input rotation speed of the intensified load spectrum; s6, determining the input torque of the intensified load spectrum; and S7, calculating the time used when the damage of the bearing under the reinforced load spectrum is equal to the total damage life of the bearing obtained in the step S3, namely, the test time of the reinforced load spectrum. According to the invention, the gear, the input rotating speed and the input torque with the largest bearing force are used as data of the strengthening test, and the damage of the bearing under the conventional load spectrum is equivalent to the strengthening test, so that the test time of the strengthening test is obtained, each parameter of the strengthening load spectrum is determined, the verification of a new bearing can be completed by only testing the gearbox after replacing the bearing according to the strengthening load spectrum, the static endurance test is not required to be carried out again, the test period is greatly shortened, and the test cost is reduced.
In summary, the gearbox reinforcement load spectrum test method aiming at bearing damage solves the technical problem that the whole gearbox needs to be subjected to static endurance test again after a part is damaged in the prior art, and the gearbox reinforcement load spectrum test method aiming at bearing damage can only carry out endurance test on the damaged part, so that the test period is greatly shortened, and the test cost is reduced.
Drawings
FIG. 1 is a flow chart of a method of the present invention for gearbox reinforcement load spectrum testing for bearing damage;
FIG. 2 is a flow chart of a first embodiment of determining input torque of FIG. 1;
FIG. 3 is a flow chart of a second embodiment of determining input torque of FIG. 1.
Detailed Description
The invention is further illustrated in the following, in conjunction with the accompanying drawings and examples.
The orientations referred to in the present specification are all relative positional relationships, and do not represent absolute positional relationships, and are shown in the drawings.
As shown in fig. 1, a method for testing a reinforced load spectrum of a gearbox aiming at bearing damage comprises the following steps:
s1, determining a test load spectrum, and counting input rotation speed, input torque and gear time under each gear in the test load spectrum;
s2, calculating the bearing damage life of each gear under the test load spectrum;
s3, calculating the total damage life of the bearing;
s4, determining a gear of the enhanced load spectrum;
s5, determining the input rotation speed of the intensified load spectrum;
s6, determining the input torque of the intensified load spectrum;
and S7, calculating the time used when the damage of the bearing under the reinforced load spectrum is equal to the total damage life of the bearing obtained in the step S3, namely, the test time of the reinforced load spectrum.
The specific implementation mode is as follows:
example 1
And firstly, calculating damage of the damaged bearing under a static endurance test load spectrum.
As shown in fig. 1, in step S1, a test load spectrum is determined, and the input rotation speed, input torque and gear time under each gear in the test load spectrum are counted, where the test load spectrum is a load spectrum used when the gearbox performs a conventional static endurance test, and the load spectrum used is different due to different models of the gearbox, and the test load spectrum is a prior art, so that the test load spectrum is not listed one by one.
As shown in fig. 1, in step S2, the rotational speed and torque of the gear of the gearbox under each working condition are calculated according to the input rotational speed and input torque counted in step S1, the bearing rotational speed and stress of each gear are calculated according to the rotational speed and torque of the gear, and the bearing damage life of each gear is calculated according to the bearing rotational speed and stress of each gear and the gear time.
The specific calculation steps are as follows:
according to the working principle of each gear of the automatic gearbox, the rotating speed and the torque of a gear of the automatic gearbox under each working condition of the gears are calculated according to the input rotating speed and the input torque counted in the step S1, and the bearing rotating speed and the bearing stress of each gear are calculated according to the rotating speed and the torque of the gear.
Torque of the gear: t=ti×ka
Rotational speed of the gear: n=ni Ka
Wherein:
ti-input Torque
Ni-input rotation speed
Ka-gear ratio calculated to gear
a-gear number.
And calculating the stress of the gear according to the torque T of the gear:
tangential force generated by the gear:
radial force generated by the gear:
axial force generated by the gear:
wherein:
d-diameter of gear pitch circle
Alpha-gear pressure angle
Beta-gear helix angle.
The forces generated by the gears are born by the bearings, so that the forces obtained by the above are bearing forces, the rotating speed n of the bearings and the forces Fa and Fr are calculated, and the bearing damage service life of each working condition of each gear is calculated according to ISO281 bearing damage calculation standards.
Basic rated life:
wherein:
c-basic rated dynamic load (the basic rated dynamic load is fixed after the bearing is selected, determined by the nature of the bearing)
P-equivalent dynamic load, the bearing only bears axial force, equivalent dynamic load is Fa, the bearing only bears radial force, equivalent dynamic load is Fr
N is the rotation speed, and the rotation speed of the bearing is calculated according to the transmission ratio by the input rotation speed.
Setting basic rated time:
wherein:
the reliability coefficient is generally 1, and the corrected rated life with the reliability of more than 90% is calculated
-life correction factor
Wherein:
ec-pollution coefficient
Cu-fatigue limit load
P-equivalent dynamic load
k-viscosity ratio
Rate of damage to the bearing = on time/Lnm, resulting in damage to the bearing in each gear.
As shown in fig. 1, in step S3, according to the fatigue equivalent accumulation theory, the bearing damage lives of the gears calculated in step S2 are respectively accumulated and summed, so as to calculate the total damage of the bearing under the static endurance test load spectrum. The total damage of the bearing is used for equivalent damage of the bearing under the reinforced load spectrum, so that the test time under the reinforced load spectrum is determined.
And secondly, formulating a reinforced load spectrum.
As shown in fig. 1, in step S4, a gear is determined. According to the transmission principle of the multi-gear automatic gearbox, the stress of the bearing under each gear is calculated, and the gear with the largest bearing stress is determined. The larger the bearing stress is, the faster the damage is, and the test time of the reinforced load spectrum can be shortened, so that the gear with the largest bearing stress is selected as the gear of the reinforced load spectrum.
As shown in fig. 1, in step S5, the input rotation speed is determined. The maximum value of the engine speed of the rounding vehicle and the rotating speed of the test bed is the input rotating speed of the enhanced load spectrum. The higher the rotation speed is, the faster the bearing loss is, and the verification time can be shortened, but the rotation speed is required to be according to the test bed capacity and the rotation speed bearing capacity of the whole engine, so that the maximum rotation speed borne by the whole engine and the test bed is taken as the input rotation speed of the reinforced load spectrum.
As shown collectively in fig. 1 and 2, in step S6, an input torque is determined. The input torque is related to the bearing capacity of the clutch and the gear, the larger the input torque is, the shorter the test time of the bearing is, namely the shorter the time for strengthening the load spectrum is, but after the input torque exceeds the bearing capacity of the clutch and the gear, the clutch and the gear are damaged, and the bearing strength cannot be verified any more due to the damage of the gearbox, so that the proper input torque is required to be formulated as the input torque for strengthening the load spectrum according to the bearing capacity of each clutch and each gear.
Firstly, preliminarily determining input torque, so that the preliminarily determined input torque is smaller than the bearing capacity of a clutch, then calculating the safety coefficient of a gear according to the preliminarily determined input torque, and determining the preliminarily determined input torque as the input torque of a reinforced load spectrum if the calculated safety coefficient of the gear meets the reliability requirement of the gear; if the calculated safety coefficient of the gear does not meet the reliability requirement of the gear, the preliminarily determined input torque value is reduced, and then the gear safety coefficient is calculated until the calculated gear safety coefficient meets the reliability requirement of the gear.
The specific steps for initially determining the input torque are as follows:
s610, calculating clutch torque capacity according to the following formula
Wherein:
bearing axial force of clutch
Mu-coefficient of friction plate
N-number of friction plates
-outer diameter of friction plate
-inner diameter of friction plate
Eta friction
Wherein, the calculation formula of the bearing axial force of the clutch is as follows
Where Fo is the stress of the clutch oil chamber, and the calculation formula is
Dpo-outer diameter of piston
Dpi-inner diameter of piston
P-the oil pressure of the clutch,
fp is the axial force generated by balancing the centrifugal force of lubricating oil in a piston cavity, and the calculation formula is
ρ -density of oil
w-rotational speed of piston
Rpo-outer radius of piston
Rpi-inner radius of piston
-inlet radius of oil into piston chamber
Wherein Fs is the stress of the return spring, and the calculation formula is
-the stress of the return spring after installation
K-spring stiffness coefficient
X-running travel after spring stress
Fb is an axial force generated by balancing the centrifugal force of lubricating oil in a piston cavity, and a calculation formula is
ρ -density of oil
w-rotation speed of balance piston
-balancing the outer diameter of the piston
-balancing the inner diameter of the piston
-inlet radius of oil into balance piston chamber
After the torque capacity Te of the clutch is calculated, the process advances to step S611.
S611, an input torque is calculated, the input torque T' =te/transmission ratio is calculated, and the process proceeds to step S612.
S612, primarily determining the input torque T' as the input torque of the intensified load spectrum, and then verifying the gear bearing capacity of the input torque.
The verification of the gear bearing capacity comprises the following steps:
and S613, calculating the torque T of the gear according to the preliminarily determined input torque T ', wherein a calculation formula is T=T', and the step S614 is performed.
S614, calculating the stress Ft of the gear according to the torque T of the gear, and entering step S615.
S615, calculating contact stress and bending stress of the gear according to the stress of the gear, and calculating the safety coefficient of the gear according to the contact stress and the bending stress of the gear.
The calculation formula of the contact stress:
contact stress of the first gear:
contact stress of the second gear:
the calculation formula of the bending stress:
wherein, the liquid crystal display device comprises a liquid crystal display device,
the meaning of each parameter in the formula is referred to as service life calculation under the variable load condition of GB_T3480, and the details are not described herein.
Contact safety coefficient of gear = contact stress/allowable contact stress,
bending safety coefficient of gear = bending stress/allowable bending stress,
the allowable contact stress and allowable bending stress are determined by the material of the gear and the like, and are well known data, and the specific calculation method thereof will not be described here.
S616, judging whether the safety coefficient of the gear is larger than 1.2, if the contact safety coefficient and the bending safety coefficient of the gear are both larger than 1.2, meeting the requirement of the reliability of the gear, namely meeting the bearing capacity of the gear, and determining the input torque T' as the input torque of the reinforced load spectrum; if either or both of the contact safety coefficient and the bending safety coefficient of the gear are smaller than 1.2, the gear reliability requirement is not satisfied, and the process proceeds to step S617.
S617, the preliminarily determined input torque T 'is reduced, and then the steps S612 to S616 are repeated until the contact safety coefficient and the bending safety coefficient of the gear are both larger than 1.2, and the input torque T' meeting the requirement is determined as the input torque of the intensified load spectrum.
As shown in fig. 1, in step S7, from the gear determined in step S4, the input rotation speed determined in step S5, and the input torque determined in step S6, as test parameters, the time taken for reaching the bearing damage obtained in step S3 is calculated according to the ISO281 bearing damage calculation standard, and the time is determined as the test time of the enhanced load spectrum, thereby determining the test parameters of the enhanced load spectrum. The gear, the input rotating speed and the input torque adopted by the enhanced load spectrum are all the working conditions with the greatest damage to the bearing, so that the test time of the enhanced load spectrum can be greatly shortened, and the damage rate which is the same as that of the gearbox running under the conventional static endurance test load spectrum for thirty days can be achieved only by two or three days, thereby greatly reducing the test time of the gearbox after the bearing is replaced, shortening the test period and reducing the test cost.
Example two
As shown in fig. 1 and 3, this embodiment is substantially the same as the first embodiment except that:
in step S6, the specific steps of preliminarily determining the input torque are as follows:
s620, empirically giving a numerical value as an input torque estimated value;
s621, multiplying the input torque predicted value by the transmission ratio of the clutch to obtain the predicted clutch torque;
s622, calculating the torque capacity of the clutch, wherein the method for calculating the torque capacity of the clutch is the same as that in the first embodiment, so the details are not described here;
s623, comparing the estimated clutch torque with the torque capacity of the clutch, judging whether the estimated clutch torque is smaller than the torque capacity of the clutch, if so, proceeding to step S624, and determining that the given input torque predicted value is the preliminarily determined input torque. If the estimated clutch torque is greater than the torque capacity of the clutch, step S629 is entered to reduce the input torque estimate, and step S620 to step S623 are repeated until the estimated clutch torque is less than the torque capacity of the clutch, and step S624 is entered to determine the input torque of the enhanced load spectrum.
Since steps S625 to S628 are identical to steps S613 to S616 in the first embodiment, the description of steps S613 to S616 in the first embodiment will be omitted herein.
In summary, the gear, the input rotating speed and the input torque with the largest bearing stress are adopted as data of the strengthening test, and damage of the bearing under the conventional load spectrum is equivalent to the strengthening test, so that the test time of the strengthening test is obtained, each parameter of the strengthening load spectrum is determined, the verification of a new bearing can be completed by only testing the gearbox after the bearing is replaced according to the strengthening load spectrum, the static endurance test is not required, the test period is greatly shortened, and the test cost is reduced.
The present invention is not limited to the above-described specific embodiments, and various modifications may be made by those skilled in the art without inventive effort from the above-described concepts, and are within the scope of the present invention.

Claims (5)

1. The gearbox reinforced load spectrum test method aiming at bearing damage is characterized by comprising the following steps of:
s1, determining a test load spectrum, and counting the input rotation speed, the input torque and the gear time of each gear in the test load spectrum;
s2, calculating the bearing damage life of each gear under the test load spectrum;
s3, calculating the total damage life of the bearing;
s4, determining a gear of the enhanced load spectrum;
s5, determining the input rotation speed of the enhanced load spectrum;
s6, determining the input torque of the intensified load spectrum;
step S7, calculating the time when the damage of the bearing under the reinforced load spectrum is equal to the total damage life of the bearing obtained in the step S3, namely, the test time of the reinforced load spectrum;
in the step S4, according to the transmission principle of the multi-gear gearbox, the stress of the bearing under each gear is calculated, and the gear with the largest stress of the bearing is determined to be the gear with the intensified load spectrum;
in the step S5, the maximum value of the engine speed of the rounding vehicle and the rotation speed of the test bed is the input rotation speed of the enhanced load spectrum;
in the step S6, firstly, the input torque is preliminarily determined so that the preliminarily determined input torque is smaller than the bearing capacity of the clutch, then, the safety coefficient of the gear is calculated according to the preliminarily determined input torque, and if the calculated safety coefficient of the gear meets the reliability requirement of the gear, the preliminarily determined input torque is determined as the input torque of the strengthening load spectrum; if the calculated safety coefficient of the gear does not meet the reliability requirement of the gear, reducing the preliminarily determined input torque value, and then calculating the safety coefficient of the gear until the calculated safety coefficient of the gear meets the reliability requirement of the gear;
the safety coefficient of the gear is calculated as follows:
calculating the torque of the gear according to the preliminarily determined input torque;
calculating the stress of the gear according to the torque of the gear;
calculating the contact stress and bending stress of the gear according to the stress of the gear;
calculating the safety coefficient of the gear according to the contact stress and the bending stress of the gear;
the safety coefficient of the gear is larger than 1.2, and the reliability requirement of the gear is met.
2. The method for testing the reinforcement load spectrum of the gearbox for bearing damage according to claim 1, wherein in the step S2, the rotational speed and the torque of the gear of the gearbox under each working condition are calculated according to the input rotational speed and the input torque counted in the step S1, the bearing rotational speed and the bearing stress of each gear are calculated according to the rotational speed and the torque of the gear, and the bearing damage life of each gear is calculated according to the bearing rotational speed and the bearing stress of each gear and the gear time.
3. The method according to claim 2, wherein in the step S3, the bearing damage lives of the respective gears calculated in the step S2 are respectively accumulated and summed according to a fatigue equivalent accumulation theory, so as to calculate the total bearing damage life.
4. The method of claim 1, wherein the step of initially determining the input torque is as follows:
calculating the torque capacity of the clutch;
the torque capacity of the clutch is divided by the gear ratio of the clutch to obtain a value which is the preliminarily determined input torque.
5. The method of claim 1, wherein the step of initially determining the input torque is as follows:
giving a numerical value as an input torque predicted value;
multiplying the input torque predicted value by the transmission ratio of the clutch to obtain the estimated clutch torque;
calculating the torque capacity of the clutch;
comparing the estimated clutch torque with the torque capacity of the clutch, and if the estimated clutch torque is smaller than the torque capacity of the clutch, determining a given input torque estimated value as the preliminarily determined input torque; if the estimated clutch torque is larger than the torque capacity of the clutch, the input torque estimated value is reduced, and the steps are repeated until the estimated clutch torque is smaller than the torque capacity of the clutch.
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