Electrically-closed high-power precision gear energy-saving transmission intelligent test bench

Abstract

According to the electrically-closed high-power precision gear energy-saving transmission intelligent test bed, a whole set of design is carried out on the test bed from the aspects of function requirements, motion control, loading modes, data acquisition and the like, the test bed is completely built, software and hardware debugging is carried out, and finally the test shows that the test bed has good performance. The test bed is composed of an electromechanical energy-saving transmission system, a control system and a test system, an application and implementation method of an electric sealing technology on the test bed is constructed, and a moving part strain acquisition scheme and a design and installation method of a device are provided. The test bench can provide driving force for the gear transmission system and can simulate loads under different working conditions; different gear transmission systems can be tested; expansibility and extensibility are achieved, a motion function, a test function and a data acquisition function are achieved, and high precision and accuracy are achieved; a friendly and easy-to-operate man-machine interaction interface is provided; and the purposes of energy conservation and environmental protection are achieved.

Description

Technical Field

[0001] The present application relates to a precision gear energy-saving transmission intelligent test bench, and in particular to an electrically enclosed high-power precision gear energy-saving transmission intelligent test bench, belonging to the technical field of precision gear transmission test benches. Background Art

[0002] With the rapid advancement and continuous development of high-speed rail, aerospace, automobiles, ships, wind power, metallurgy, mining and other fields, the demand for high-power gear transmission systems is increasing, and the requirements for their performance are also getting higher and higher. At this stage, high-speed and heavy-load, efficient and reliable, intelligent and precise gear transmission is a key scientific and technological research project. The high-precision and cutting-edge problems of gear transmission systems have always been a bottleneck problem restricting the development of high-end equipment manufacturing industry. In order to ensure that the gear transmission system can achieve reliable operation, stable transmission, low vibration and noise, and long service life under complex working conditions and the alternating effects of various excitation factors, it is necessary to conduct in-depth research on various aspects of the gear transmission system in simulation and testing.

[0003] However, due to the constraints of cost and technical difficulties, the application of test methods in gear characteristics is relatively rare, and the development of test technology is also limited, limited to the single function of the test bench. However, testing is a very important means of studying gear transmission performance, and simulation methods idealize and simplify many factors, resulting in differences from actual conditions. Simulation results can only be used as a reference, but not as a basis. Only through real experiments can the research results be relatively reliable and credible.

[0004] There are still many technical difficulties in the design and research of test benches for high-power gear transmission systems. In terms of transmission systems, control systems, test systems, and loading methods, more in-depth research and technical advancement are needed to build a test bench with more comprehensive functions, more stable performance, and more reliable results. The test design after the test bench is built should be considered at the same time as the test bench construction stage, and the installation layout of all devices should be considered comprehensively.

[0005] The technical research and development of high-power gearbox test bench can promote the progress and development of gear transmission system test bench, provide reference for the construction of gear transmission system test bench in the future, and build a gear transmission system test bench to conduct experimental research and analysis on the performance of the gear transmission system, which can truly reflect the influencing factors and conditions of the gear transmission system performance, and provide a reliable basis for the design optimization of the gearbox. At the same time, the electric closed loading technology can make the test bench compact, save energy, and have high application value and development prospects.

[0006] The problems that need to be solved by the existing high-power gear transmission test bench and the key technical difficulties of this application include:

[0007] (1) Due to the constraints of cost and technical difficulties, the application of gear characteristic test methods is relatively small, and the development of test technology is also limited. It is limited to the single function of the test bench. The gear transmission simulation method idealizes and simplifies many factors, resulting in differences from the actual situation. The simulation results can only be used as a reference, but not as a basis. Only through real tests can the research results be relatively reliable and credible. There are still many technical difficulties in the design and research of test benches for high-power gear transmission systems. There is a lack of more in-depth research and technical advancement in the transmission system, control system, test system and loading method, and it is impossible to build a test bench with more comprehensive functions, more stable performance and more reliable results. The test design is not considered at the same time during the test bench construction stage, and there is a lack of overall consideration of the installation layout of all devices. It is impossible to build a gear transmission system test to conduct experimental research and analysis on the performance of the gear transmission system. It is impossible to truly reflect the factors and conditions that affect the performance of the gear transmission system, and it is impossible to provide a reliable basis for the design optimization of the gearbox. At the same time, there is a lack of electric closed loading technology, the test bench structure is not compact, and the energy consumption is large.

[0008] (2) The existing high-power gear transmission system test bench cannot meet the necessary technical requirements. The test bench cannot provide driving force for the gear transmission system and cannot simulate the load under different working conditions. The test bench has poor versatility and cannot test different gear transmission systems. The test bench has poor scalability and extensibility and cannot implement different test studies on the gear transmission system when adding different test systems, and cannot expand the functions of the test bench. The test bench lacks precision and accuracy. The test lacks a friendly and easy-to-operate human-computer interaction interface. The test bench cannot achieve the goal of energy saving and environmental protection.

[0009] (3) The test bench of the prior art does not have the function of simulating motion under different working conditions and different working states, is not suitable for gearboxes with one input shaft and one output shaft, and cannot be fully applied to forward drive, forward drag, reverse drive and reverse drag, etc. The test bench lacks test functions such as preliminary design no-load test, efficiency test, planetary gear load-balancing test and gear transmission system dynamic response test. It is impossible to detect whether the processing and manufacturing accuracy of the gearbox and the assembly quality of the entire electromechanical energy-saving transmission can meet the design requirements, and it is impossible to test the working state and performance of the gearbox under the condition of adding load, and it is impossible to test the load-balancing situation between the planetary gears. Due to the influence of various incentive factors such as complex working conditions, manufacturing errors, installation errors and lubrication, it is difficult to ensure the load-balancing characteristics of the planetary gear transmission system. The speed and torque adjustment performance of the test bench is poor, including the acceleration speed, torque increase, and the stability of speed and torque. They cannot meet the requirements, which is not conducive to improving the safety and reliability performance, smooth operation performance and service life of the gear transmission system.

[0010] (4) The test bench of the prior art cannot realize the comprehensive data acquisition function, cannot fully collect the motor speed, torque and gear contact stress, etc., lacks the measurement of speed and torque, and is more difficult to collect gear contact stress. It is impossible to collect stress through strain gauges and process and store it by the acquisition card, and it is impossible to transmit it to the host computer through wireless communication for final display and processing. The operating status of the test bench cannot meet the requirements. There are major shortcomings in dynamic response and strain acquisition. The reliability and accuracy of data acquisition are poor. It cannot provide comprehensive and reliable detection for high-power precision gear transmission, which is not conducive to ensuring that the gear transmission system can work efficiently and reliably, with smooth transmission and low vibration and noise under complex working conditions and the alternating effects of multiple excitation factors. Summary of the invention

[0011] This application builds a test bench for a high-power gear transmission system, and conducts a complete set of design for the test bench from the aspects of functional requirements, motion control, loading methods, and data acquisition. The test bench is fully built and the software and hardware are debugged. Finally, the test bench is tested to have good performance. The test bench consists of electromechanical energy-saving transmission, control system and test system. The design of the transmission system is aimed at the design of the structure and size parameters of the gearbox. The control system is aimed at the speed regulation and torque regulation of the motor, including the design of the control circuit, the design and installation of the control cabinet, and the design of the control software. The test system is designed for different test data acquisition systems. The application and implementation method of the electric closure technology on the test bench is constructed, and the design and installation method of the moving parts strain acquisition scheme and device are proposed. The test bench is specially designed to improve the adjustment method of the motor's speed and torque. It can provide driving force for the gear transmission system and simulate loads under different working conditions. It has a certain versatility and can test different gear transmission systems. The test bench has a certain scalability and extensibility, and can implement different test studies on the gear transmission system when adding different test systems, thereby expanding the function of the test bench. The test bench has motion functions, test functions and data acquisition functions, etc., with high precision and accuracy; it has a relatively friendly and easy-to-operate human-computer interaction interface; it also achieves the purpose of energy saving and environmental protection.

[0012] In order to achieve the above technical effects, the technical solutions adopted in this application are as follows:

[0013] The electrically enclosed high-power precision gear energy-saving transmission intelligent test bench is designed and constructed from the functional requirements, motion control, loading mode and data acquisition aspects. The test bench is fully built and the software and hardware are debugged. The test bench consists of electromechanical energy-saving transmission, control system and test system. The transmission system is designed for the structure and size parameters of the gearbox, and the control system is for the speed regulation and torque control of the motor, including the design of the control circuit, the design and installation of the control cabinet and the design of the control software. There are multiple test systems, and different test data acquisition and test systems are built for different tests, including the load-balancing performance of the planetary gear, the transmission efficiency of the system, the wear and lubrication test of the gears; in terms of motion control, the S120 multi-axis drive system is improved to control and adjust the speed of the drive motor and the output torque of the load motor to achieve adjustable speed and load. The entire control system is based on PLCS7-1200 as the core control unit, and a touch screen is used for human-computer interaction;

[0014] The loading method of the test bench is based on electric power closure. The load motor converts mechanical energy into electrical energy and then feeds it back to the drive motor. Based on the difficulty of grid connection in electric closure technology, the test bench adopts the method of common DC bus for grid connection. On the drive motor side, the 380V AC power rectifier is converted into DC power, and the DC power is then converted into AC power through the inverter to supply the drive motor; on the load motor side, the AC power generated by the load motor is connected to the inverter, and then the inverter is connected to the DC power supply on the drive motor side to complete the DC grid connection and form an electric power closed loop.

[0015] A-Hardware design of the test bench: First, build the overall hardware solution of the test bench, determine the overall structure and overall composition of the test bench, then establish the composition and design scheme of the electromechanical energy-saving transmission, motion control system and data acquisition and processing system respectively, and build the application and implementation method of electric sealing technology on the test bench, and establish the scheme of strain collection of moving parts and the design and installation method of the device in the data acquisition part;

[0016] B- Software design of the test bench: First, build the overall structure and framework of the software system based on the software system requirements of the test bench, and then establish the functions and design solutions of the motion control software and data acquisition and processing software, especially improve the speed and torque adjustment methods of the motor.

[0017] Preferably, the overall hardware structure of the test bench includes: electromechanical energy-saving transmission, control system and data acquisition and processing system, integrating mechanical transmission, motor drive, motor loading, measurement control and computer monitoring structure;

[0018] The control system realizes the motion control of the motor and generator, and realizes the grid-connected feedback of the common DC bus; the electromechanical energy-saving transmission drives the gearbox and loads the gearbox to simulate its working condition; the data acquisition system collects various signals required for the test, and is stored and processed by the host computer.

[0019] Preferably, electromechanical energy-saving transmission: the electromechanical energy-saving transmission is composed of a motor, a gear transmission system, a torque sensor and a coupling, which are mounted and fixed on the same T-slot cast iron platform, and their center heights are unified through the base, and then connected into a whole;

[0020] 1-Gearbox

[0021] For the planetary gear load-sharing performance test, a composite planetary gearbox based on the Ravingneaux structure is used, which consists of two sun gears, two sets of planetary gear sets and an inner ring gear. The transmission ratio of this gearbox is 2:1.

[0022] Some parts of the gearbox are equipped with multiple different structures for replacement. In addition to the standard internal gear ring with a standard width that matches the number of teeth and module, 8 additional internal gear rings of the same size as the standard internal gear ring are also configured for replacement. Among the 8 replacement internal gear rings, four are with grooves, four are without grooves, and there is also an internal gear ring without grooves.

[0023] A total of 8 standard gears, including sun gears s1, s2 and planetary gears al, a2, a3, b1, b2, and b3, can be replaced with gears with different degrees of eccentricity errors. The eccentricity errors are realized in three different sizes of 20μm, 30μm, and 40μm, and eccentric sleeves are used.

[0024] The sun gears s1 and s2 can change their respective support stiffnesses respectively, and rigid support or floating support can be achieved by adding elastic shafts at both ends.

[0025] The inner gear ring and each gear are easy to disassemble and install to achieve the above replacement. The conical matching form is adopted. The matching taper ensures reliable connection and convenient disassembly. According to the matching conditions and the maximum load designed to be transmitted, the design of the circumferential key required for the inner gear ring is calculated and determined to ensure the circumferential fixation of the inner gear ring on the frame;

[0026] The axial spacing between the two sun gears inside the compound planetary gearbox is kept at 50mm, leaving enough space for the strain gauge to be attached to the root of the sun gear teeth, and for the installation of components required for the test system such as the acquisition card. A slot is reserved on the top of the box as an observation hole. The observation hole is located between the two sun gears and is sealed with tempered glass. The hole is circular with a diameter of 80mm.

[0027] A position error is set for the mounting hole of the planetary gear on the planetary carrier along the meshing line direction, that is, the position of the mounting hole of the planetary gear is required to have a position offset compared with the standard installation, and the offset direction of the error is along the meshing direction of s1 and a and the meshing direction of s2 and r, and the offset displacement is 20μm. For the planetary gear set a, it is only required to change the position error of the planetary gear al, and offset it by 20μm in the direction of the tensile meshing line and the compression meshing line respectively, and provide two planetary carriers with mounting hole position errors; similarly, the planetary gear set b also provides two additional planetary carriers with mounting hole position errors;

[0028] The gearbox realizes the working condition: sun gear s1 input, sun gear s2 output, and its maximum load torque is 1.5kNm.

[0029] 2- Equipment selection

[0030] 1) Motor: Use a motor with a power of 90Kw;

[0031] 2) Torque sensor: Use non-contact torque sensor to test and collect torque and speed data of various rotating bodies, including: 1) Torque measurement; 2) Non-contact transmission of energy and signals; 3) Digital output signal; 4) Test real-time torque and quickly and accurately obtain dynamic and static torque data; 5) Whether the rotating body is rotating or stationary, regardless of the direction of rotation, the required signal can be collected; 6) When continuously testing the forward and reverse torque, there is no need to repeatedly adjust the zero; Installation notes of this torque sensor: 1) When installed horizontally, both rigid couplings and flexible couplings can be used to ensure that the couplings are close to the shaft shoulders at both ends of the sensor; 2) When using a rigid coupling for connection, the coaxiality requirement is high and should be guaranteed to be less than 0.05mm, while when using a flexible coupling, the coaxiality should be guaranteed to be less than 0.2mm;

[0032] (3) Coupling: Consider the size of the shaft and the torque transmitted when selecting, and use an elastic coupling;

[0033] (4) T-slot cast iron platform: The size of the cast iron platform is 4m*1m. The size of the T-slot is matched with M12 bolts. It is evenly distributed along the width of the platform, and a T-slot is opened every 100mm.

[0034] (5) Tightening and clamping parts: The entire set of electromechanical energy-saving transmission is clamped and fixed on the T-slot. First, the T-slot and the equipment installation through hole are connected by bolts. However, the installation holes of some equipment cannot be aligned with the T-slot. At this time, a pressure plate is used for clamping and fixing.

[0035] Preferably, the hardware selection and system construction of the motion control system: the motion control system adopts S120 multi-axis driver, the control unit adopts CU320, the speed, torque and position of each motor output shaft are controlled, the motors connected under the same control unit share data, the power interface module is connected between the power grid and the power module, the active power module plays the role of a rectifier, rectifies the three-phase AC into DC, and then feeds the DC back to the power grid, and can also control the voltage on the DC bus in a closed loop. The control unit controls the active power module through the DRIVE-CLIQ communication cable through the DRIVE-CLIQ interface, the motor module converts 540V or 600V DC into three-phase AC, the motor is connected to the motor module to control the motor speed and torque, and at the same time, the motor's own encoder feeds back the motor speed to the motor module through the encoder module to achieve closed-loop control.

[0036] Preferably, the circuit design of the motion control system:

[0037] (1) Power supply circuit design: The power supplies required by the components of the control system include AC380V, AC220V, and DC24V. The 380V AC power supply is connected to the power interface module and ultimately provides power to the motor. The 220V AC power supply is obtained by stepping down the 380V AC power supply through a transformer. The 220V AC power supply is converted by a switching power supply to obtain a 24V DC power supply, which is used as a control and enable power supply.

[0038] (2) Design of control system components wiring diagram:

[0039] 1) The power interface module is connected to the power module and needs to be connected to a 380V AC power supply and a 24V DC power supply;

[0040] 2) Two motors are directly connected under the two motor modules, powered by a 24V power supply, and connected to the power module through a DC bus;

[0041] Preferably, the test bench is closed in terms of power: a common DC bus is used. First, a 380V power supply is converted into 600V DC power through a rectifier to form a DC bus. Two inverters are connected to the DC bus to connect two motors respectively. The output shafts of the two motors are connected together by a transmission system. One of the two motors works in an electric state to obtain energy from the DC bus, and the other motor works in a power generation state to feed back energy to the DC bus. The energy is transmitted and shared in the DC bus to form a closed loop. Only a small part of the energy is lost by the transmission system, and the lost part is supplemented by the external power grid, that is, the 380V AC power supply. The power module serves as a rectifier, and the motor module serves as an inverter. The inverter converts DC power into AC power for the motor. It can also work in reverse, that is, convert the AC power generated by the generator into DC power and feed it back to the DC bus.

[0042] The electric motor is set to speed mode and its speed can be set arbitrarily within the rated speed range to drive the operation of the transmission system; the generator is set to torque mode and its speed can be set arbitrarily within the rated torque. The key to allowing the generator to load the transmission system is to set its torque direction to be opposite to the speed direction of the output shaft of the transmission system, so that there is a reverse torque effect, and a load is added to the transmission system when it is running. At the same time, the generator and the electric motor are motors of the same model. The generator does not rotate itself in torque mode, and is then driven by the electric motor through the transmission system. In this way, its speed is opposite to the direction of its own output torque and is dragged in the opposite direction. At this time, it is working in a power generation state, which is equivalent to a generator.

[0043] Preferably, the data acquisition and processing system:

[0044] 1-Torque signal acquisition: Torque acquisition is measured by torque sensor, and the data acquisition card collects and processes analog signals and performs A / D conversion. Finally, the digital signal is transmitted to the host computer for storage, display and digital signal processing to obtain the required information; the torque sensor output is 4-20mA current signal, and the PCI bus data acquisition card is selected, which is a computer expansion card, to obtain electrical or non-electrical signals from sensors or other devices under test, and then send them to the host computer for processing and analysis; the host computer uses an industrial computer and installs LabVIEW data acquisition and processing software;

[0045] 2- Temperature signal acquisition: Use temperature sensor to measure temperature change, the output electrical signal is collected and processed by data acquisition card and A / D conversion is performed, a conditioning circuit is added, the voltage signal is amplified and filtered, and then transmitted to the host computer;

[0046] 3- Strain signal acquisition: The strain signal collected by the test bench is the root stress of the rotating gear. The strain signal is first collected by the strain gauge, then transmitted to the acquisition circuit for processing, and the data is stored in the memory card, and then transmitted to the host computer by the wireless communication module; the specific design scheme of the acquisition device includes:

[0047] (1) The bridge circuit uses 0.01% ultra-high precision low temperature drift resistors to ensure high precision, high stability and low temperature drift performance. The instrument amplifier chip adopts the mature INA125U+INA126UA solution;

[0048] (2) A fifth-order Butterworth 10KHZ low-pass filter is used to implement the anti-aliasing filter design of the signal. The filter uses Murata 0805 1% high-precision high-frequency capacitors and 5% high-precision high-frequency laminated inductors;

[0049] (3) A 0.5ppm high-precision active temperature-compensated crystal oscillator is used to achieve a highly stable and reliable clock source to ensure that within the 2s interval of the clock synchronization pulse, the clock synchronization accuracy between each acquisition node can be stabilized within the 1s range;

[0050] (4) The mature 16-bit high-precision sampling circuit design is realized by combining the ±1.6mv, 3ppm ultra-low temperature drift high-precision reference source ADR444B with the ultra-small 16-bit 8-channel high-precision AD chip AD7689;

[0051] (5) Use CPLD reliable parallel timing circuit to control multiple wireless communication modules in different channels and working frequencies to achieve wireless multi-channel synchronous sampling with parallel signal transmission and adaptive hysteresis compensation;

[0052] (6) Adopt Fatfs file system to realize large-capacity miniSD card storage management;

[0053] (7) LabView and Matlab are used to build an easy-to-use and friendly user-oriented interface to facilitate subsequent data analysis and processing;

[0054] (8) Based on the motion and vibration conditions during the test and taking into account the size of the circuit board, high-reliability surface mount sockets and buckle plugs are used as the connectors of the circuit board;

[0055] (9) Use dedicated ESD devices for electrostatic protection, TVS diodes for transient voltage protection, distributed capacitors for power supply stabilization, and linear LDO to reduce system noise;

[0056] 4-Signal acquisition anti-interference

[0057] Connect the control cabinet and the shell grounding terminals of each component in the control cabinet to the ground, separate the power line and the signal line, install the power source and the signal source in different control cabinets, and use shielded twisted pair cables for all signal lines. Twist the signal lines together to make the distance between them and the interference source as equal as possible, and make the distributed capacitance as equal as possible to reduce electromagnetic interference. The conditioning circuit after the temperature sensor and the filter circuit in the strain acquisition card play an anti-interference role.

[0058] Preferably, the overall structure of the software system is as follows: the motion control software is written in the host computer, then downloaded to the slave computer and used in the slave computer, while the data processing and acquisition software is written in the host computer, then installed in the host computer and used in the host computer;

[0059] The motion control software consists of two parts: the front-end part and the back-end part. The front-end part is the operation interface, which is installed in the touch screen. Human-machine interaction is through the touch screen. The back-end part controls the S120 system through PLC to control the operation of the two motors.

[0060] The data acquisition and processing software consists of two parts: static component data acquisition software and dynamic component data acquisition software. The data acquisition of static components includes the speed and torque of the torque and speed sensor, and the oil temperature of the temperature sensor. They are collected directly to the host computer through wired acquisition methods and with the help of data acquisition cards. The data collection of moving parts is the collection of gear tooth root strain. A special acquisition card is designed to collect and store the data first, and then transmit it to the host computer through wireless communication. The specially developed acquisition software in the host computer will collect, process, store and display the data.

[0061] Preferably, the motion control software is divided into two parts, one is the touch screen software, and the other is the PLC software. The touch screen, PLC and S120 system are connected together through the DRIVE-CLIQ communication cable in hardware, and data is exchanged through the DRIVE-CLIQ communication protocol. System configuration is required in software to connect all devices together at the software level.

[0062] The PLC receives the setting data and button trigger signals from the touch screen, and then transmits this information to the S120 system in the form of a message. The message contains the setting speed and torque, start and stop commands, and then controls the motor to make corresponding actions. The S120 system then feeds back the motor's operating parameters to the PLC, performs closed-loop control of the motor's speed and torque, and at the same time, the PLC transmits the motor's real-time speed and torque data to the touch screen for display;

[0063] 1-Speed ​​and torque adjustment and master-slave control

[0064] The frequency converter is used to realize the speed control and torque distribution requirements of each motor. This application of the frequency converter is master-slave control. Based on the hard connection between the drive motor and the loading motor through the gear transmission system, the control scheme adopts direct torque distribution. The control unit adopts CU320, and direct torque distribution is realized from the master-slave configuration scheme of CU320 and the hardware and software configuration of the S120 system.

[0065] The debugging of the drive system requires the use of STARTER software to determine the communication mode of the host and slave. The DRIVE-CLiQ communication mode is used. Only the control unit, motor module and host computer need to be connected with the DRIVE-CLiQ communication cable.

[0066] Then set the master-slave working mode. For the direct torque distribution scheme, set the working modes of the master and slave, wherein the master is set to the speed working mode and the slave is set to the torque working mode. When the slave is set to the torque working mode, the output of the bypass speed regulator is switched to torque through parameters.

[0067] 2-Touch screen software design

[0068] To write the touch screen software, you first need to select the device and set the device parameters in the TIA Portal V13 software, and then configure the device. Then you can design the screen and define the variables, as well as other settings such as HMI alarms.

[0069] Preferably, the data acquisition and processing software: collects analog signals or digital signals measured by the hardware device to a host computer, and stores, processes and displays them in the form of digital signals;

[0070] The strain acquisition software has three tabs, namely, gateway control center, SD card data processing and data waveform display. The gateway control center page communicates with the gateway by serial communication. Select the serial port number corresponding to the gateway in the serial port list. In the operation area, you can complete the operations of synchronizing node time, obtaining node status, stopping sampling, setting sampling duration and starting sampling. The information area displays the feedback information of the operation. Before starting sampling, synchronize the sampling time to ensure the time synchronization of each node. Starting sampling means issuing an acquisition instruction to the acquisition device, and the acquisition board starts to acquire strain signals and stores them in the SD card on the acquisition board.

[0071] The SD card data processing page reads and stores data. The data is read after the test is completed in the shutdown state. Insert the USB interface of the data cable on the integrated acquisition board into the host computer, select the drive letter corresponding to the SD card on the software, display the SD card sampling information, right-click on the record in the data acquisition list, and the Save As menu pops up. Select the saved folder, and the SD card data is saved to the txt document in the specified path of the host computer.

[0072] The data waveform display page performs data processing and waveform display. First, select the txt file previously saved in the host computer. After successfully opening it, perform subsequent operations. On this page, set the number of display points of the waveform image, the frequency division number, the waveform data page turning operation, the coefficient setting from waveform data to actual data, whether the waveform is filtered, and whether to display the measurement window.

[0073] Compared with the prior art, the innovations and advantages of this application are:

[0074] (1) This application has built a test bench for a high-power gear transmission system, and has carried out a complete set of design for the test bench from the aspects of functional requirements, motion control, loading methods and data acquisition. The test bench has been fully built and the software and hardware have been debugged. Finally, the test bench has been tested to have good performance. The test bench consists of electromechanical energy-saving transmission, control system and test system. The design of the transmission system is aimed at the design of the structure and size parameters of the gearbox. The control system is aimed at the speed regulation and torque regulation of the motor, including the design of the control circuit, the design and installation of the control cabinet and the design of the control software. The test system is designed for different test data acquisition systems. The application and implementation method of the electric closure technology on the test bench was constructed, and the design and installation method of the moving parts strain collection scheme and device were proposed. The test bench is specially designed to improve the adjustment method of the motor's speed and torque. It can provide driving force for the gear transmission system and simulate loads under different working conditions. It has a certain versatility and can test different gear transmission systems. The test bench has a certain scalability and extensibility, and can implement different test studies on the gear transmission system when adding different test systems, thereby expanding the function of the test bench. The test bench has motion functions, test functions and data acquisition functions, etc., with high precision and accuracy; it has a relatively friendly and easy-to-operate human-computer interaction interface; it also achieves the purpose of energy saving and environmental protection.

[0075] (2) The motion function of the test bench is significantly better than the existing technology. The test bench is suitable for a gearbox with one input shaft and one output shaft, and has motion functions that simulate different working conditions and different working states, including forward drive, forward drag, reverse drive and reverse drag. The test bench uses a motor to drive and load the gearbox. The rated speed of the drive motor is 1000r / min and the maximum speed is 986r / min, so the speed of the drive end can be adjusted between 0 and 986r / min. Different speeds can be set for each test. Once the speed is set and the motor is turned on, the speed will gradually increase from 0 to the set speed, and the time for the speed to increase to the set speed can be set manually. The basic principle of setting the time is to enter the working state as quickly as possible and conduct the test, while ensuring that the test bench runs smoothly during the acceleration process. The acceleration time set for this test bench is 10s. The rated torque of the loading motor is 871.7N·m, and the load torque at the loading end can be adjusted between 0 and 871.7N·m. This application has improvements in the transmission system, control system, test system, and loading method, and has built a test bench with more comprehensive functions, more stable performance, and more reliable results. The installation and layout of all devices are comprehensively considered. The test bench has reached a good operating state, with good speed and torque adjustment performance, good speed and torque stability, and can provide support for high-power gear transmission motion testing.

[0076] (3) This application designs a test bench for testing various aspects of the performance of a high-power gear transmission system, including the load-balancing performance of planetary gears, the transmission efficiency of the system, gear wear and lubrication, etc. There are multiple test systems, and different test systems need to be built for different performance tests. In terms of motion control, the speed of the drive motor and the output torque of the load motor are controlled and adjusted to achieve adjustable speed and load. The test bench is designed with test functions such as no-load test, efficiency test, planetary gear load-balancing test, and gear transmission system dynamic response test. It can detect whether the processing and manufacturing accuracy of the gearbox and the assembly quality of the entire electromechanical energy-saving transmission meet the design requirements, and can test the working state and performance of the gearbox when the load is added. The purpose of the planetary gear load-balancing test is to test the load-balancing situation between the planetary gears. Through the use of this test bench, it is helpful to improve the stability, reliability, safety and dynamic performance of the high-power precision gear transmission system, and ensure that it works smoothly, safely and reliably.

[0077] (4) The test bench of the present application has different data acquisition functions because it needs to realize multiple test functions. According to the designed test functions, the data that the test bench needs to collect include the motor speed, torque and gear contact stress. First, the speed and torque measurement must be realized. The speed is measured by the motor's built-in encoder, and the data is fed back and displayed on the touch screen. The motor speed can be calculated by the motor's variable frequency control system and displayed on the touch screen, or it can be measured by the torque sensor, and then collected by the data acquisition card, and processed and displayed in the host computer. The collection of gear contact stress is relatively complicated because the gear is in operation. The test bench collects stress through strain gauges, which are processed and stored by the acquisition card, and finally transmitted to the host computer through wireless communication for final display and processing. The test bench has strong data acquisition capabilities to ensure that the gear transmission system can achieve reliable operation, stable transmission, low vibration and noise, and long service life under complex working conditions and the alternating effects of multiple excitation factors.

[0078] (5) The motion control software of this application realizes the motion control of two motors and has the following functions: 1) A human-machine interface with clear structure and simple operation; 2) Realize the communication between the touch screen and PLC, and between the PLC and the S120 system; 3) Realize the adjustment of the output speed of the drive motor and set the appropriate acceleration time; 4) Realize the adjustment of the output torque of the load motor and set the appropriate torque increase time; 5) When shutting down, the speed and torque can be slowly reduced to stop; (6) It has a fault reporting function. The data acquisition and processing software collects the signals sent by sensors and other equipment to the host computer for processing, storage and display, and has the following functions: 1) A friendly operation interface; 2) Ability to send acquisition instructions to the acquisition equipment; 3) Ability to collect data obtained by sensors and other equipment; 4) Ability to process, store and display the collected data. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] Figure 1 It is the overall system block diagram of the electric enclosed gear transmission test bench.

[0080] Figure 2 This is the specific structure diagram of the gearbox.

[0081] Figure 3 It is the distribution diagram of the acceleration sensor measurement points.

[0082] Figure 4 This is a schematic diagram of the position error of the planetary gear mounting holes.

[0083] Figure 5 This is a schematic diagram of the main parameters of the torque sensor.

[0084] Figure 6 This is a schematic diagram of the double-arm half-bridge measurement method used for strain measurement.

[0085] Figure 7 It is the installation diagram of the strain acquisition system.

[0086] Figure 8 It is the program flow chart of PLC motion control software.

[0087] Fig. 9 It is a schematic diagram of the debugging connection of the master-slave control configuration drive system. DETAILED DESCRIPTION

[0088] The following, in conjunction with the accompanying drawings, further describes the technical solution of the electrically enclosed high-power precision gear energy-saving transmission intelligent test bench provided by the present application, so that technicians in this field can better understand the present application and implement it.

[0089] High-power gear transmission systems are used in high-speed and heavy-load conditions, such as high-speed railways, large ships, large mining machinery, oil extraction machinery, and high-power wind power equipment. With the rapid development of the national economy, these fields are also growing, and the demand for high-power gear transmission systems is increasing. At the same time, many equipments have higher and higher requirements for safety and reliability, and some equipments are not easy to maintain frequently, so the gear transmission system is required to have higher safety and reliability, stable operation and longer service life.

[0090] For the evaluation and detection of various aspects of the performance of the gear transmission system, whether it is factory inspection, evaluation and detection during the use process, fault diagnosis, or scholars' performance research on the gear transmission system, it is necessary to build a special test bench to test the performance of the gear transmission system. This project aims at the performance research of high-power gear transmission systems and designs a test bench to test some aspects of the performance of high-power gear transmission systems, such as the load-sharing performance of planetary gears, the transmission efficiency of the system, the wear and lubrication of gears, etc. The test bench consists of three parts: electromechanical energy-saving transmission, control system and test system. There are multiple test systems, and different test systems need to be built for different performance tests. In terms of motion control, the Siemens S120 multi-axis drive system is used to control and adjust the speed of the drive motor and the output torque of the load motor, so that the speed and load can be adjusted. The entire control system is controlled by Siemens PLCS7-1200 as the core control unit, and Siemens touch screen is used for human-computer interaction.

[0091] In order to achieve the purpose of energy saving, the loading method of the test bench adopts the electric power closure (abbreviated as electric closure) technology, that is, the load motor converts mechanical energy into electrical energy, and then feeds it back to the drive motor for use. It is difficult to connect to the grid during the power feedback process. If it is directly connected to the grid, the electrical energy generated by the load motor may pollute and affect the power grid due to the presence of harmonics. In view of the difficulty of connecting to the grid in the electric closure technology, the test bench adopts the method of common DC bus for grid connection. On the drive motor side, the 380V AC power rectifier is converted into a DC power supply, and the DC power supply is then converted into AC power through the inverter to supply the drive motor; on the load motor side, the AC power generated by the load motor is connected to the inverter, and then the inverter is connected to the DC power supply on the drive motor side to complete the DC grid connection and form an electric power closed loop.

[0092] After the test bench was built, performance tests and data collection tests were carried out to verify the smooth operation and reliability of the test bench and the accuracy of data collection. The results showed that the test bench achieved the expected goals and realized its expected functions.

[0093] The motion function of the test bench: The high-power gear transmission system test bench is suitable for a gearbox with one input shaft and one output shaft. To test and study the gearbox, first let the gearbox run and make it work under different speed and torque conditions to study its working performance. The test bench has the motion function of simulating different working conditions and different working states, such as forward drive, forward drag, reverse drive and reverse drag. The test bench uses a motor to drive and load the gearbox. The rated speed of the drive motor is 1000r / min and the maximum speed is 986r / min, so the speed of the drive end can be adjusted between 0 and 986r / min. Different speeds can be set for each test. Once the speed is set and the motor is turned on, the speed will gradually increase from 0 to the set speed, and the time for the speed to increase to the set speed can be set manually. The principle of setting the time is to enter the working state as quickly as possible and conduct the test, while ensuring that the test bench runs smoothly during the acceleration process. The acceleration time set for the test bench is 10s. The rated torque of the loading motor is 871.7 N·m, so the load torque at the loading end can be adjusted between 0 and 871.7 N·m.

[0094] Test bench test function: The test bench is initially designed with no-load test, efficiency test, planetary gear load test and gear transmission system dynamic response test and other test functions. The purpose of no-load test is to detect whether the processing and manufacturing accuracy of the gearbox and the assembly quality of the entire electromechanical energy-saving transmission can meet the design requirements. The specific test operation method is: first let the test bench run at low speed without load, and then gradually increase the speed after stabilization, and finally reach the rated speed. At the rated speed, the gearbox runs forward and reverse respectively, and the time is at least 1 hour. The requirements of this test are: all connectors, fasteners and clamps cannot be loose; all seals and joints must not leak or seep oil; the test bench must run smoothly without obvious vibration and impact; all parts must be fully lubricated to ensure that the bearing temperature is not too high. During the entire test process, the bearing temperature data is regularly collected and recorded, and the vibration and noise conditions are observed and recorded. The purpose of the efficiency test is to test the working state and performance of the gearbox under the condition of adding load. The specific test operation method is: set the output torque of the loading motor to load the gearbox, and the gearbox under test runs at the speed set by the drive motor. The gearbox rotation speed gradually increases from small to the rated speed of the drive motor. During the entire test process, it is necessary to measure and record the test data regularly. The data has the following parameters: input speed, input torque, output speed, output torque and efficiency. In order to improve the accuracy of the data and reduce the interference of accidental factors, for each working condition, it is required to collect multiple sets of data, and record the collection time of each set of data at the same time. The data recorded each time should be the average value of multiple sets of measurement data. The purpose of the planetary gear load balance test is to test the load balance between each planetary gear. The planetary transmission system is a kind of gear transmission. Due to its compact structure and strong load-bearing capacity, it is more widely used than the fixed-axis gear transmission system. At the same time, due to the symmetry of the distribution of the planetary gears, the radial loads on the bearings are balanced, so the service life will be longer. Due to the special structure and many advantages of the planetary gear transmission system, higher requirements are put forward for its motion stability and load distribution uniformity. However, in actual engineering applications, due to the influence of complex working conditions, manufacturing errors, installation errors, lubrication and other incentive factors, it is difficult to ensure the load-sharing characteristics of the planetary gear transmission system. If the load on all planetary gears is evenly distributed, the number of planetary gears can be further increased, which can make the structure of the planetary transmission system more compact. On the contrary, if the load between the planetary gears is uneven, these advantages of the planetary gear transmission system will be difficult to play. Therefore, in the design process of the planetary transmission system, a very important task is to consider the load-sharing problem between the planetary gears so that the load on them is as uniform as possible. In this case, it is particularly important to conduct a load-sharing test on the planetary gears. The specific test method is: evenly paste strain gauges at the root of the sun gear teeth, measure the meshing stress between the planetary gears and the sun gear, calculate the load-sharing coefficient, and then analyze its load-sharing characteristics.

[0095] Data acquisition function of the test bench: Since the test bench needs to realize multiple test functions, it needs to have different data acquisition functions. According to the designed test functions, the data that the test bench needs to collect include motor speed, torque, and gear contact stress. First of all, the speed and torque measurement must be realized. The speed is measured by the motor's built-in encoder, and the data is fed back and displayed on the touch screen. The motor speed can be calculated by the motor's variable frequency control system and displayed on the touch screen, or it can be measured by the torque sensor, and then collected by the data acquisition card, and processed and displayed in the host computer. The collection of gear contact stress is relatively complicated because the gear is in operation. The test bench collects stress through strain gauges, which are processed and stored by the acquisition card, and finally transmitted to the host computer through wireless communication for final display and processing.

[0096] 1. Hardware Design of Test Bench

[0097] (I) Overall structure of the test bench

[0098] The test bench includes electromechanical energy-saving transmission, control system and data acquisition and processing system, integrating mechanical transmission, motor drive, motor loading, measurement control and computer monitoring structure. The overall system block diagram of the test bench is as follows Figure 1 shown.

[0099] The control system realizes the motion control of the motor and generator, and realizes the grid-connected feedback of the common DC bus; the electromechanical energy-saving transmission drives the gearbox and loads the gearbox to simulate its working condition; the data acquisition system collects various signals required for the test, and is stored and processed by the host computer.

[0100] (II) Electromechanical energy-saving transmission

[0101] The electromechanical energy-saving transmission consists of a motor, a gear transmission system, a torque sensor and a coupling, which are installed and fixed on the same T-slot cast iron platform, and their center heights are unified through the base and then connected into a whole.

[0102] 1. Gearbox

[0103] For the planetary gear load balancing performance test, a composite planetary gearbox based on the Ravingneaux structure is used, which consists of two sun gears, two sets of planetary gear sets and an inner ring gear. The transmission ratio of the gearbox is 2:1. The specific structure of the gearbox is as follows: Figure 2 .

[0104] Some parts of the gearbox are set up with multiple different structures for replacement. In addition to the standard internal gear ring with a standard width that matches the number of teeth and module, 8 additional internal gear rings of the same size as the standard internal gear ring are also configured for replacement. Among the 8 replacement internal gear rings, four are with grooves and four are without grooves (the internal gear ring without grooves is the standard internal gear ring). The respective slot sizes and positions of the four internal gear rings with grooves are shown in Figure 3 There is also an unslotted internal gear ring.

[0105] A total of 8 standard gears, including sun gears s1, s2 and planetary gears al, a2, a3, b1, b2, and b3, can be replaced with gears with different degrees of eccentricity errors. The eccentricity errors are realized in three different sizes of 20μm, 30μm, and 40μm, and eccentric sleeves are used.

[0106] The sun gears s1 and s2 can change their respective support stiffnesses respectively, and rigid support or floating support can be achieved by adding elastic shafts at both ends.

[0107] The inner gear ring and each gear are easy to disassemble and install to achieve the above replacement. A conical matching form is adopted, and the matching taper ensures reliable connection and convenient disassembly. According to the matching conditions and the maximum load designed to be transmitted, the design of the circumferential key required for the inner gear ring is calculated and determined to ensure the circumferential fixation of the inner gear ring on the frame.

[0108] The axial spacing between the two sun gears inside the compound planetary gearbox is maintained at 50mm, leaving enough space for attaching strain gauges to the root of the sun gear teeth and installing components required for the test system such as acquisition cards. A slot is reserved on the top of the box as an observation hole. The observation hole is located between the two sun gears and is sealed with tempered glass. The hole is circular with a diameter of 80mm.

[0109] The position error is set for the mounting hole of the planetary gear on the planetary carrier along the meshing line direction, that is, the position of the mounting hole of the planetary gear is required to have a position offset compared with the standard installation, such as Figure 4 The error offset direction is along the meshing direction of s1 and a and the meshing direction of s2 and r, and the offset displacement is 20μm. For planetary gear set a, it is only required to change the position error of planetary gear al, and offset it by 20μm in the direction of the tensile meshing line and the compression meshing line respectively, and provide two planetary carriers with mounting hole position errors; similarly, planetary gear set b also provides two additional planetary carriers with mounting hole position errors.

[0110] The gearbox realizes the working condition: sun gear s1 input, sun gear s2 output, and its maximum load torque is 1.5kNm.

[0111] 2. Equipment selection

[0112] (1) Motor: Use a motor with a power of 90Kw;

[0113] (2) Torque sensor: A non-contact torque sensor is used. Detailed parameters are as follows: Figure 5 As shown; testing and collecting torque and speed data of various rotating bodies, including: 1) torque measurement; 2) non-contact transmission of energy and signals; 3) digital output signal; 4) testing real-time torque, quickly and accurately obtaining dynamic and static torque data; 5) whether the rotating body is rotating or stationary, regardless of the direction of rotation, the required signal can be collected; 6) when continuously testing the forward and reverse torque, there is no need to repeat zeroing; installation notes of the torque sensor: 1) When installed horizontally, both rigid couplings and flexible couplings can be used to ensure that the couplings are close to the shaft shoulders at both ends of the sensor; 2) When using a rigid coupling for connection, the coaxiality requirements are high and should be guaranteed to be less than 0.05mm, while when using a flexible coupling, the coaxiality should be guaranteed to be less than 0.2mm.

[0114] (3) Coupling: Consider the size of the shaft and the torque transmitted when selecting, and use an elastic coupling;

[0115] (4) T-slot cast iron platform: The size of the cast iron platform is 4m*1m. The size of the T-slot is matched with M12 bolts. It is evenly distributed along the width of the platform, and a T-slot is opened every 100mm.

[0116] (5) Tightening and clamping parts: The entire set of electromechanical energy-saving transmission is clamped and fixed on the T-slot. First, the T-slot and the equipment installation through hole are connected by bolts. However, the installation holes of some equipment cannot be aligned with the T-slot. At this time, a pressure plate is used for clamping and fixing;

[0117] (III) Motion control system

[0118] 1. Hardware selection and system construction

[0119] The motion control system uses S120 multi-axis driver and the control unit uses CU320 to control the speed, torque and position of each motor output shaft. The motors connected to the same control unit share data. The power interface module is connected between the power grid and the power module. The active power module plays the role of a rectifier, rectifying the three-phase AC power into DC power, and then feeding the DC power back to the power grid. It can also perform closed-loop control of the voltage on the DC bus. The control unit uses DRIVE-CLIQ communication cable to control the active power module through the DRIVE-CLIQ interface. The motor module converts 540V or 600V DC power into three-phase AC power. The motor is connected to the motor module to control the motor speed and torque. At the same time, the motor's built-in encoder feeds back the motor speed to the motor module through the encoder module to achieve closed-loop control.

[0120] 2. Circuit Design

[0121] (1) Power circuit design

[0122] The power supplies required by the components of the control system include AC380V, AC220V, and DC24V. The 380V AC power supply is connected to the power interface module and ultimately provides power for the motor. The 220V AC power supply is obtained by stepping down the 380V AC power supply through a transformer. The 220V AC power supply is converted by a switching power supply to obtain a 24V DC power supply, which is used as a control and enabling power supply.

[0123] (2) Design of control system components wiring diagram

[0124] 1) The power interface module is connected to the power module and needs to be connected to a 380V AC power supply and a 24V DC power supply;

[0125] 2) Two motors are directly connected under the two motor modules, powered by a 24V power supply, and connected to the power module through a DC bus;

[0126] 3. Test bench electrical power closed

[0127] A common DC bus is used. First, the 380V power supply is converted into 600V DC through a rectifier to form a DC bus. Two inverters are connected to the DC bus to connect two motors respectively. The output shafts of the two motors are connected together by a transmission system. One of the two motors works in an electric state and obtains energy from the DC bus, and the other motor works in a power generation state and feeds energy back to the DC bus. The energy is transmitted and shared in the DC bus to form a closed loop. Only a small part of the energy is lost by the transmission system, and the lost part is supplemented by the external power grid, that is, the 380V AC power supply. The power module acts as a rectifier and the motor module acts as an inverter. The inverter converts DC power into AC power for the motor. It can also work in reverse, that is, convert the AC power generated by the generator into DC power and feed it back to the DC bus.

[0128] The electric motor is set to speed mode and its speed can be set arbitrarily within the rated speed range to drive the operation of the transmission system; the generator is set to torque mode and its speed can be set arbitrarily within the rated torque. The key to allowing the generator to load the transmission system is to set its torque direction to be opposite to the speed direction of the output shaft of the transmission system, so that there is a reverse torque effect, and a load is added to the transmission system when it is running. At the same time, the generator and the electric motor are motors of the same model. The generator does not rotate itself in torque mode, and is then driven by the electric motor through the transmission system. In this way, its speed is opposite to the direction of its own output torque and is dragged in the opposite direction. At this time, it is working in a power generation state, which is equivalent to a generator.

[0129] (IV) Data acquisition and processing system

[0130] 1. Torque signal acquisition

[0131] Torque acquisition is measured by the torque sensor, which is collected and processed by the data acquisition card and A / D conversion is performed. Finally, the digital signal is transmitted to the host computer for storage, display and digital signal processing to obtain the required information; the torque sensor output is 4-20mA current signal, and a PCI bus data acquisition card is selected, which is a computer expansion card. It obtains electrical or non-electrical signals from sensors or other devices under test, and then sends them to the host computer for processing and analysis; the host computer uses an industrial computer and installs LabVIEW data acquisition and processing software.

[0132] 2. Temperature signal acquisition

[0133] A temperature sensor is used to measure temperature changes. The output electrical signal is collected and processed by a data acquisition card and A / D conversion is performed. A conditioning circuit is added to amplify and filter the voltage signal and then transmit it to the host computer.

[0134] 3. Strain signal acquisition

[0135] The strain signal collected by the test bench is the root stress of the rotating gear. The strain signal is first collected by the strain gauge, then transmitted to the acquisition circuit for processing, and the data is stored in the memory card, and then transmitted to the host computer by the wireless communication module.

[0136] The selected strain gauge size should be as small as possible, with a resistance of 120Ω, and the strain measurement should adopt the standard double-arm half-bridge measurement method, such as Figure 6 That is, one strain measurement interface requires two strain gauges, and they need to be installed complementary, that is, one is mounted on the tension side and the other is mounted on the compression side. The subsequent circuit amplifies the AC pressure difference and performs AD sampling to obtain the vibration waveform.

[0137] The acquisition device is installed on the gear and rotates together. The acquisition circuit, storage card and wireless communication module are integrated on the designed acquisition board, which is easy to install and seal, and has high integration and small size.

[0138] (1) Design of strain acquisition device

[0139] The strain collection device in the prior art is in the form of a collection box or a collection box, which requires continuous power supply from 220V AC or a large-size lithium battery for continuous power supply. It is difficult to meet the needs of occasions with limited installation space, small lithium battery power supply, multi-channel synchronous collection, and operation of collection components. Therefore, it is necessary to design a strain collection device with low power consumption, small size, wireless synchronous sampling, and large-capacity and high-speed local storage.

[0140] The acquisition device includes a wireless acquisition node and a synchronous timing gateway module. The wireless acquisition node is set with 16-bit accuracy and 8-channel synchronous strain sampling. A 0.5ppm high-precision active temperature-compensated clock circuit is used on the board. While ensuring the 1us synchronization accuracy between nodes, the synchronous timing interval can be as long as 2s. The synchronous timing gateway module concurrently controls multiple 2.4G communication modules working at adjacent frequencies in different channels to achieve automatic multi-channel communication time delay measurement and adaptive high-precision synchronous pulse signal broadcasting. The host computer software reads the data in the SD card of each acquisition node and uses LabView and Matlab to build a user-oriented interface.

[0141] The specific design of the collection device includes:

[0142] (1) The bridge circuit uses 0.01% ultra-high precision low temperature drift resistors to ensure high precision, high stability and low temperature drift performance. The instrument amplifier chip adopts the mature INA125U+INA126UA solution;

[0143] (2) A fifth-order Butterworth 10KHZ low-pass filter is used to implement the anti-aliasing filter design of the signal. The filter uses Murata 0805 1% high-precision high-frequency capacitors and 5% high-precision high-frequency laminated inductors;

[0144] (3) A 0.5ppm high-precision active temperature-compensated crystal oscillator is used to achieve a highly stable and reliable clock source to ensure that within the 2s interval of the clock synchronization pulse, the clock synchronization accuracy between each acquisition node can be stabilized within the 1s range;

[0145] (4) The mature 16-bit high-precision sampling circuit design is realized by combining the ±1.6mv, 3ppm ultra-low temperature drift high-precision reference source ADR444B with the ultra-small 16-bit 8-channel high-precision AD chip AD7689;

[0146] (5) Use CPLD reliable parallel timing circuit to control multiple wireless communication modules in different channels and working frequencies to achieve wireless multi-channel synchronous sampling with parallel signal transmission and adaptive hysteresis compensation;

[0147] (6) Use Fatfs file system to implement large-capacity miniSD card storage management;

[0148] (7) LabView and Matlab are used to build an easy-to-use and friendly user-oriented interface to facilitate subsequent data analysis and processing;

[0149] (8) Based on the motion and vibration conditions during the test and taking into account the size of the circuit board, high-reliability surface mount sockets and buckle plugs are used as the connectors of the circuit board;

[0150] (9) Use dedicated ESD devices for electrostatic protection, TVS diodes for transient voltage protection, distributed capacitors for power supply stabilization, and linear LDO to reduce system noise.

[0151] (2) Installation of strain acquisition system

[0152] The acquisition card is provided with mounting holes, and the corresponding mounting screw holes are processed at the end of the gear to be tested. The acquisition card is fixed to the end of the gear with bolts. The accessories of the acquisition card include antenna, power supply battery and external data cable. The signal transmitter of the antenna, the battery and the USB connector of the data cable need to be placed outside the gear box and fixed on the running shaft outside the gear box. At the same time, the antenna signal line, power line and data line are led out from the acquisition card to the outside of the gear box, and a through hole is opened at the axis, and then all the lines are led out from the through hole. The installation diagram of the strain system is as follows: Figure 7 .

[0153] 4. Signal acquisition and anti-interference

[0154] Connect the control cabinet and the shell grounding terminals of each component in the control cabinet to the ground, separate the power line and the signal line, install the power source and the signal source in different control cabinets, and use shielded twisted pair cables for all signal lines. Twist the signal lines together to make the distance between them and the interference source as equal as possible, and make the distributed capacitance as equal as possible to reduce electromagnetic interference. The conditioning circuit after the temperature sensor and the filter circuit in the strain acquisition card play an anti-interference role.

[0155] The acquisition software of the test bench has added filtering programs in LABVIEW to make the collected waveforms smoother and the main lines clearer.

[0156] 2. Software Design of Test Bench

[0157] It includes motion control software and data acquisition and processing software, which realizes control tasks and the acquisition and processing of different signals based on hardware construction. Software design includes PLC programming, touch screen programming and program writing for data acquisition, processing, storage and display in the host computer.

[0158] (I) Overall structure of the software system

[0159] The motion control software is written in the host computer, then downloaded to the slave computer and used in the slave computer, while the data processing and acquisition software is written in the host computer, then installed in the host computer and used in the host computer.

[0160] The motion control software consists of two parts: the front-end part and the back-end part. The front-end part is the operation interface, which is installed in the touch screen. Human-computer interaction is through the touch screen. The back-end part controls the S120 system through PLC to control the operation of the two motors.

[0161] The data acquisition and processing software consists of two parts: static component data acquisition software and dynamic component data acquisition software. The data acquisition of static components includes the speed and torque of the torque and speed sensor, and the oil temperature of the temperature sensor. They are collected directly to the host computer through wired acquisition methods and with the help of data acquisition cards. The data collection of moving parts is the collection of gear tooth root strain. A special acquisition card is designed to collect and store the data first, and then transmit it to the host computer through wireless communication. The specially developed acquisition software in the host computer will collect, process, store and display the data.

[0162] (II) Motion Control Software

[0163] The motion control software is divided into two parts, one is the touch screen software, and the other is the PLC software. The touch screen, PLC and S120 system are connected together in hardware through DRIVE-CLIQ communication cables, and data is exchanged through the DRIVE-CLIQ communication protocol. System configuration is required in software to connect all devices together at the software level.

[0164] The PLC receives the setting data and button trigger signal from the touch screen, and then transmits this information to the S120 system in the form of a message. The message contains the setting speed and torque, start and stop commands, and then controls the motor to make corresponding actions. The S120 system then feeds back the motor's operating parameters to the PLC, performs closed-loop control of the motor's speed and torque, and at the same time, the PLC transmits the motor's real-time speed and torque data to the touch screen for display. The program flow chart of the PLC software is shown below. Figure 8 shown.

[0165] 1. Speed ​​and torque adjustment and master-slave control

[0166] In an industrial control environment where a frequency converter controls the operation of a motor, due to special working conditions or the capacity limitation of the frequency converter, two or more motors are running at the same time to drive a transmission system. At this time, it is necessary to ensure that all motors have the same speed and can evenly distribute torque. Therefore, a frequency converter is needed to achieve the speed control and torque distribution requirements of each motor. This application of the frequency converter is master-slave control.

[0167] Based on the hard connection between the driving motor and the loading motor through the gear transmission system, the control scheme adopts direct torque distribution. The control unit adopts CU320, and direct torque distribution is realized from the master-slave configuration scheme of CU320 and the hardware and software configuration of the S120 system.

[0168] (1) CU320 master-slave configuration scheme

[0169] When using CU320 for master-slave control, the master and slave need to exchange data. The multiple axes of CU320 are directly connected using DRIVE-CLIQ communication cables.

[0170] (2) Master-slave control configuration of S120 system

[0171] For the master-slave control of the S120 system, the whole system must be debugged first. The drive system must be connected before debugging. The connection diagram is as follows: Fig. 9 shown.

[0172] The debugging of the drive system requires the use of STARTER software to determine the communication method between the host and the slave. The DRIVE-CLiQ communication method is used. Only the DRIVE-CLiQ communication cable is used to connect the control unit, motor module and host computer. The wiring method is simple, not easily disturbed, and the communication is more stable and reliable.

[0173] Then set the master-slave working mode. For the direct torque distribution scheme, set the working modes of the master and slave, wherein the master is set to the speed working mode and the slave is set to the torque working mode. When the slave is set to the torque working mode, the output of the bypass speed regulator is switched to torque through parameters.

[0174] First, set the slave's torque to work in speed mode, set parameter P1300 = 20 or 21, then set P1501 to switch the working mode from speed mode to torque mode, and finally connect the slave torque setting source at P1503 to the master's torque, and set the master's torque parameter to r079.

[0175] 2. Touch screen software design

[0176] To write the touch screen software, you first need to select the device and set the device parameters in the TIA Portal V13 software, and then configure the device. Then you can design the screen and define the variables, as well as other settings such as HMI alarms.

[0177] The touch screen software has a root screen (initial main interface) and a Motor screen (operation sub-interface). The initial main interface is the interface entered when the touch screen is started. It displays the name of the control software. There are also home page, ENTER and F1 to F8 buttons. Touch the ENTER button to enter the operation sub-interface.

[0178] On the left side of the operation sub-interface are the status indicators of the drive motor and the load motor, on the upper right side are the power enable switch and the motor enable switch, as well as the start and stop buttons. On the lower side are the speed setting box for the drive motor and the torque setting box for the load motor. In addition, there is a window to display the actual speed and torque of the drive motor and the load motor that are fed back.

[0179] 3. Data acquisition and processing software

[0180] The data acquisition and processing software collects the analog or digital signals measured by the hardware equipment to the host computer, and stores, processes and displays them in the form of digital signals.

[0181] The strain acquisition software has three tabs, namely, gateway control center, SD card data processing and data waveform display. The gateway control center page communicates with the gateway by serial communication. Select the serial port number corresponding to the gateway in the serial port list. In the operation area, you can complete the operations of synchronizing node time, obtaining node status, stopping sampling, setting sampling duration and starting sampling. The information area displays the feedback information of the operation. Before starting sampling, synchronize the sampling time to ensure the time synchronization of each node. Starting sampling means issuing an acquisition instruction to the acquisition device. The acquisition board starts to acquire strain signals and stores them in the SD card on the acquisition board.

[0182] The SD card data processing page reads and stores data. The data is read after the test is completed in the shutdown state. Insert the USB interface of the data cable on the integrated acquisition board into the host computer, select the drive letter corresponding to the SD card on the software, display the SD card sampling information, right-click on the record in the data acquisition list, and the Save As menu pops up. Select the saved folder, and the SD card data is saved to the txt document in the specified path of the host computer.

[0183] The data waveform display page performs data processing and waveform display. First, select the txt file previously saved in the host computer. After successfully opening it, perform subsequent operations. On this page, set the number of display points of the waveform image, the frequency division number (based on a sampling frequency of 20K), the waveform data page turning operation, the coefficient setting from waveform data to actual data, whether the waveform is filtered, and whether to display the measurement window.

[0184] In addition, on the data waveform, right-click to pop up the menu, and then set the display channel, set the mouse wheel zoom axis, control the mouse to display the line value, and copy the waveform.

[0185] 3. Experiment and Analysis

[0186] After the test bench was built, two tests were carried out to verify the performance of the test bench. First, an operation test was designed to give the test bench an initial run-in and achieve a good operating state. At the same time, the speed and torque adjustment performance of the test bench was tested, including acceleration speed, torque increase, and stable speed and torque retention. The results showed that the operation of the test bench met the design requirements; then, an acquisition test was designed, taking dynamic response testing and strain acquisition as examples to verify the reliability and accuracy of data acquisition. The results showed that the test bench could collect data normally and achieved the test function.

Claims

1. Electric closed high-power precision gear energy-saving transmission intelligent test bench, characterized by: The test bench is designed and constructed from the functional requirements, motion control, loading mode and data acquisition aspects. The test bench is fully built and the software and hardware are debugged. The test bench consists of electromechanical energy-saving transmission, control system and test system. The transmission system is designed for the structure and size parameters of the gearbox, and the control system is for the speed regulation and torque control of the motor, including the design of the control circuit, the design and installation of the control cabinet and the design of the control software. There are multiple test systems, and different test data acquisition and test systems are built for different tests, including the load-balancing performance of the planetary gear, the transmission efficiency of the system, the wear and lubrication test of the gears; in terms of motion control, the S120 multi-axis drive system is improved to control and adjust the speed of the drive motor and the output torque of the load motor to achieve adjustable speed and load. The entire control system is based on PLCS7-1200 as the core control unit, and a touch screen is used for human-computer interaction; The loading method of the test bench is based on electric power closure. The load motor converts mechanical energy into electrical energy and then feeds it back to the drive motor. Based on the difficulty of grid connection in electric closure technology, the test bench adopts the method of common DC bus for grid connection. On the drive motor side, the 380V AC power rectifier is converted into DC power, and the DC power is then converted into AC power through the inverter to supply the drive motor; on the load motor side, the AC power generated by the load motor is connected to the inverter, and then the inverter is connected to the DC power supply on the drive motor side to complete the DC grid connection and form an electric power closed loop. A-Hardware design of the test bench: First, build the overall hardware solution of the test bench, determine the overall structure and overall composition of the test bench, then establish the composition and design scheme of the electromechanical energy-saving transmission, motion control system and data acquisition and processing system respectively, and build the application and implementation method of electric sealing technology on the test bench, and establish the scheme of strain collection of moving parts and the design and installation method of the device in the data acquisition part; B- Software design of the test bench: First, build the overall structure and framework of the software system based on the software system requirements of the test bench, and then establish the functions and design solutions of the motion control software and data acquisition and processing software, especially improve the speed and torque adjustment methods of the motor.

2. According to claim 1, the electrically enclosed high-power precision gear energy-saving transmission intelligent test bench is characterized in that: The overall hardware structure of the test bench includes electromechanical energy-saving transmission, control system and data acquisition and processing system, integrating mechanical transmission, motor drive, motor loading, measurement control and computer monitoring structure; The control system realizes the motion control of the motor and generator, and realizes the grid-connected feedback of the common DC bus; the electromechanical energy-saving transmission drives the gearbox and loads the gearbox to simulate its working condition; the data acquisition system collects various signals required for the test, and is stored and processed by the host computer.

3. According to claim 1, the electrically enclosed high-power precision gear energy-saving transmission intelligent test bench is characterized in that: Electromechanical energy-saving transmission: Electromechanical energy-saving transmission consists of a motor, a gear transmission system, a torque sensor and a coupling. They are installed and fixed on the same T-slot cast iron platform, and their center heights are unified through the base, and then connected into a whole; 1-Gearbox For the planetary gear load-sharing performance test, a composite planetary gearbox based on the Ravingneaux structure is used, which consists of two sun gears, two sets of planetary gear sets and an inner ring gear. The transmission ratio of this gearbox is 2:

1. Some parts of the gearbox are equipped with multiple different structures for replacement. In addition to the standard internal gear ring with a standard width that matches the number of teeth and module, 8 additional internal gear rings of the same size as the standard internal gear ring are also configured for replacement. Among the 8 replacement internal gear rings, four are with grooves, four are without grooves, and there is also an internal gear ring without grooves. A total of 8 standard gears, including sun gears s1, s2 and planetary gears a1, a2, a3, b1, b2, and b3, can be replaced with gears with different degrees of eccentricity errors. The eccentricity errors are 20μm, 30μm, and 40μm in three different sizes, and eccentric sleeves are used; Sun gears s1 and s2 can change their respective support stiffness, and realize rigid support or floating support by adding elastic shafts at both ends; The inner gear ring and each gear are easy to disassemble and install to achieve the above replacement. The conical matching form is adopted. The matching taper ensures reliable connection and convenient disassembly. According to the matching conditions and the maximum load designed to be transmitted, the design of the circumferential key required for the inner gear ring is calculated and determined to ensure the circumferential fixation of the inner gear ring on the frame; The axial spacing between the two sun gears inside the compound planetary gearbox is kept at 50mm, leaving enough space for the strain gauge to be attached to the root of the sun gear teeth, and for the installation of components required for the test system such as the acquisition card. A slot is reserved on the top of the box as an observation hole. The observation hole is located between the two sun gears and is sealed with tempered glass. The hole is circular with a diameter of 80mm. A position error is set for the mounting hole of the planetary gear on the planetary carrier along the meshing line direction, that is, the position of the mounting hole of the planetary gear is required to have a position offset compared with the standard installation, and the offset direction of the error is along the meshing direction of s1 and a and the meshing direction of s2 and r, and the offset displacement is 20μm. For the planetary gear set a, only the position error of the planetary gear al is required to be changed, and it is offset by 20μm in the direction of the tensile meshing line and the compressive meshing line respectively, and two planetary carriers with mounting hole position errors are provided; Similarly, planetary gear set b also provides two additional planet carriers with mounting hole position errors; The gearbox realizes the working condition: sun gear s1 input, sun gear s2 output, and its maximum load torque is 1.5kNm; 2- Equipment selection 1) Motor: Use a motor with a power of 90Kw; 2) Torque sensor: Use non-contact torque sensor to test and collect torque and speed data of various rotating bodies, including: 1) Torque measurement; 2) Non-contact transmission of energy and signals; 3) Digital output signal; 4) Test real-time torque and quickly and accurately obtain dynamic and static torque data; 5) Whether the rotating body is rotating or stationary, regardless of the direction of rotation, the required signal can be collected; 6) When continuously testing the forward and reverse torque, there is no need to repeatedly adjust the zero; Installation notes of this torque sensor: 1) When installed horizontally, both rigid couplings and flexible couplings can be used to ensure that the couplings are close to the shaft shoulders at both ends of the sensor; 2) When using a rigid coupling for connection, the coaxiality requirement is high and should be guaranteed to be less than 0.05mm, while when using a flexible coupling, the coaxiality should be guaranteed to be less than 0.2mm; (3) Coupling: Consider the size of the shaft and the torque transmitted when selecting, and use an elastic coupling; (4) T-slot cast iron platform: The size of the cast iron platform is 4m*1m. The size of the T-slot is matched with M12 bolts. It is evenly distributed along the width of the platform, and a T-slot is opened every 100mm. (5) Tightening and clamping parts: The entire set of electromechanical energy-saving transmission is clamped and fixed on the T-slot. First, the T-slot and the equipment installation through hole are connected by bolts. However, the installation holes of some equipment cannot be aligned with the T-slot. At this time, a pressure plate is used for clamping and fixing.

4. According to claim 1, the electrically enclosed high-power precision gear energy-saving transmission intelligent test bench is characterized in that: Hardware selection and system construction of motion control system: The motion control system adopts S120 multi-axis driver and CU320 control unit to control the speed, torque and position of each motor output shaft. The motors connected under the same control unit share data. The power interface module is connected between the power grid and the power module. The active power module plays the role of rectifier, rectifying the three-phase AC into DC, and then feeding the DC back to the power grid. It can also control the voltage on the DC bus in a closed loop. The control unit uses DRIVE-CLIQ communication cable to control the active power module through the DRIVE-CLIQ interface. The motor module converts 540V or 600V DC into three-phase AC. The motor is connected to the motor module to control the motor speed and torque. At the same time, the motor's built-in encoder feeds back the motor speed to the motor module through the encoder module to achieve closed-loop control.

5. According to claim 1, the electrically enclosed high-power precision gear energy-saving transmission intelligent test bench is characterized in that: Circuit design of motion control system: (1) Power supply circuit design: The power supplies required by the components of the control system include AC380V, AC220V, and DC24V. The 380V AC power supply is connected to the power interface module and ultimately provides power to the motor. The 220V AC power supply is obtained by stepping down the 380V AC power supply through a transformer. The 220V AC power supply is converted by a switching power supply to obtain a 24V DC power supply, which is used as a control and enable power supply. (2) Design of control system components wiring diagram: 1) The power interface module is connected to the power module and needs to be connected to a 380V AC power supply and a 24V DC power supply; 2) Two motors are directly connected under the two motor modules, powered by a 24V power supply, and connected to the power module through a DC bus.

6. According to claim 1, the electrically enclosed high-power precision gear energy-saving transmission intelligent test bench is characterized in that: The test bench is closed in power: a common DC bus is used. First, the 380V power supply is converted into 600V DC power through a rectifier to form a DC bus. Two inverters are connected to the DC bus to connect two motors respectively. The output shafts of the two motors are connected together by a transmission system. One of the two motors works in an electric state and obtains energy from the DC bus. The other motor works in a power generation state and feeds energy back to the DC bus. The energy is transmitted and shared in the DC bus to form a closed loop. Only a small part of the energy is lost by the transmission system, and the lost part is supplemented by the external power grid, that is, the 380V AC power supply. The power module serves as a rectifier and the motor module serves as an inverter. The inverter converts DC power into AC power for the motor. It can also work in reverse, that is, convert the AC power generated by the generator into DC power and feed it back to the DC bus. The electric motor is set to speed mode and its speed can be set arbitrarily within the rated speed range to drive the operation of the transmission system; the generator is set to torque mode and its speed can be set arbitrarily within the rated torque. The key to allowing the generator to load the transmission system is to set its torque direction to be opposite to the speed direction of the output shaft of the transmission system, so that there is a reverse torque effect, and a load is added to the transmission system when it is running. At the same time, the generator and the electric motor are motors of the same model. The generator does not rotate itself in torque mode, and is then driven by the electric motor through the transmission system. In this way, its speed is opposite to the direction of its own output torque and is dragged in the opposite direction. At this time, it is working in a power generation state, which is equivalent to a generator.

7. According to claim 1, the electrically enclosed high-power precision gear energy-saving transmission intelligent test bench is characterized in that: Data acquisition and processing system: 1-Torque signal acquisition: Torque acquisition is measured by torque sensor, and the data acquisition card collects and processes analog signals and performs A / D conversion. Finally, the digital signal is transmitted to the host computer for storage, display and digital signal processing to obtain the required information; the torque sensor output is 4-20mA current signal, and the PCI bus data acquisition card is selected, which is a computer expansion card, to obtain electrical or non-electrical signals from sensors or other devices under test, and then send them to the host computer for processing and analysis; the host computer uses an industrial computer and installs LabVIEW data acquisition and processing software; 2- Temperature signal acquisition: Use temperature sensor to measure temperature change, the output electrical signal is collected and processed by data acquisition card and A / D conversion is performed, a conditioning circuit is added, the voltage signal is amplified and filtered, and then transmitted to the host computer; 3- Strain signal acquisition: The strain signal collected by the test bench is the root stress of the rotating gear. The strain signal is first collected by the strain gauge, then transmitted to the acquisition circuit for processing, and the data is stored in the memory card, and then transmitted to the host computer by the wireless communication module; the specific design scheme of the acquisition device includes: (1) The bridge circuit uses 0.01% ultra-high precision low temperature drift resistors to ensure high precision, high stability and low temperature drift performance. The instrument amplifier chip adopts the mature INA125U+INA126UA solution; (2) A fifth-order Butterworth 10KHZ low-pass filter is used to implement the anti-aliasing filter design of the signal. The filter uses Murata 0805 1% high-precision high-frequency capacitors and 5% high-precision high-frequency laminated inductors; (3) A 0.5ppm high-precision active temperature-compensated crystal oscillator is used to achieve a highly stable and reliable clock source to ensure that within the 2s interval of the clock synchronization pulse, the clock synchronization accuracy between each acquisition node can be stabilized within the 1s range; (4) The mature 16-bit high-precision sampling circuit design is realized by combining the ±1.6mv, 3ppm ultra-low temperature drift high-precision reference source ADR444B with the ultra-small 16-bit 8-channel high-precision AD chip AD7689; (5) Use CPLD reliable parallel timing circuit to control multiple wireless communication modules in different channels and working frequencies to achieve wireless multi-channel synchronous sampling with parallel signal transmission and adaptive hysteresis compensation; (6) Adopt Fatfs file system to realize large-capacity miniSD card storage management; (7) LabView and Matlab are used to build an easy-to-use and friendly user-oriented interface to facilitate subsequent data analysis and processing; (8) Based on the motion and vibration conditions during the test and taking into account the size of the circuit board, high-reliability surface mount sockets and buckle plugs are used as the connectors of the circuit board; (9) Use dedicated ESD devices for electrostatic protection, TVS diodes for transient voltage protection, distributed capacitors for power supply stabilization, and linear LDO to reduce system noise; 4-Signal acquisition anti-interference The control cabinet and the shell grounding terminals of each component in the control cabinet are uniformly connected to the earth, the power line and the signal line are wired separately, the power supply and signal source are installed in different control cabinets, all signal lines use shielded twisted pair cables, the signal lines are twisted together to make the distance between them and the interference source as consistent as possible, and the distributed capacitance as consistent as possible to reduce electromagnetic interference. The conditioning circuit after the temperature sensor and the filtering circuit in the strain acquisition card both play an anti-interference role.

8. According to claim 1, the electrically enclosed high-power precision gear energy-saving transmission intelligent test bench is characterized in that: Overall structure of the software system: the motion control software is written in the host computer, then downloaded to the slave computer and used in the slave computer, while the data processing and acquisition software is written in the host computer, then installed in the host computer and used in the host computer; The motion control software consists of two parts: the front-end part and the back-end part. The front-end part is the operation interface, which is installed in the touch screen. Human-machine interaction is through the touch screen. The back-end part controls the S120 system through PLC to control the operation of the two motors. The data acquisition and processing software consists of two parts: static component data acquisition software and dynamic component data acquisition software. The data acquisition of static components includes the speed and torque of the torque and speed sensor, and the oil temperature of the temperature sensor. They are collected directly to the host computer through wired acquisition methods and with the help of data acquisition cards. The data collection of moving parts is the collection of gear tooth root strain. A special acquisition card is designed to collect and store the data first, and then transmit it to the host computer through wireless communication. The specially developed acquisition software in the host computer will collect, process, store and display the data.

9. The electrically enclosed high-power precision gear energy-saving transmission intelligent test bench according to claim 1 is characterized in that: The motion control software is divided into two parts, one is the touch screen software, the other is the PLC software. The touch screen, PLC and S120 system are connected together through the DRIVE-CLIQ communication cable in hardware, and data is exchanged through the DRIVE-CLIQ communication protocol. System configuration is required in software to connect all devices together at the software level. The PLC receives the setting data and button trigger signals from the touch screen, and then transmits this information to the S120 system in the form of a message. The message contains the setting speed and torque, start and stop commands, and then controls the motor to make corresponding actions. The S120 system then feeds back the motor's operating parameters to the PLC, performs closed-loop control of the motor's speed and torque, and at the same time, the PLC transmits the motor's real-time speed and torque data to the touch screen for display; 1-Speed ​​and torque adjustment and master-slave control The inverter is used to realize the speed control and torque distribution requirements of each motor. This application of the inverter is master-slave control. Based on the hard connection between the drive motor and the loading motor through the gear transmission system, the control scheme adopts direct torque distribution. The control unit adopts CU320, and direct torque distribution is realized from the master-slave configuration scheme of CU320 and the hardware and software configuration of the S120 system. The debugging of the drive system requires the use of STARTER software to determine the communication mode of the host and slave. The DRIVE-CLiQ communication mode is used. Only the control unit, motor module and host computer need to be connected with the DRIVE-CLiQ communication cable. Then, the master-slave working mode is set. For the direct torque distribution scheme, the working modes of the master and slave are set, wherein the master is set to the speed working mode and the slave is set to the torque working mode. When the slave is set to the torque working mode, the output of the bypass speed regulator is switched to torque through parameters; 2-Touch screen software design To write the touch screen software, you first need to select the device and set the device parameters in the TIA Portal V13 software, and then configure the device. Then you can design the screen and define the variables, as well as other settings such as HMI alarms.

10. The electrically enclosed high-power precision gear energy-saving transmission intelligent test bench according to claim 1 is characterized in that: Data acquisition and processing software: collects analog or digital signals measured by hardware equipment to the host computer, and stores, processes and displays them in the form of digital signals; The strain acquisition software has three tabs, namely, gateway control center, SD card data processing and data waveform display. The gateway control center page communicates with the gateway by serial communication. Select the serial port number corresponding to the gateway in the serial port list. In the operation area, you can complete the operations of synchronizing node time, obtaining node status, stopping sampling, setting sampling duration and starting sampling. The information area displays the feedback information of the operation. Before starting sampling, synchronize the sampling time to ensure the time synchronization of each node. Starting sampling means issuing an acquisition instruction to the acquisition device, and the acquisition board starts to acquire strain signals and stores them in the SD card on the acquisition board. The SD card data processing page reads and stores data. The data is read after the test is completed in the shutdown state. Insert the USB interface of the data cable on the integrated acquisition board into the host computer, select the drive letter corresponding to the SD card on the software, and display the SD card sampling information. Right-click on the record in the data acquisition list, and the Save As menu pops up. Select the folder to save. The data on the SD card is saved to a txt document in the path specified by the host computer. The data waveform display page performs data processing and waveform display. First, select the txt file previously saved in the host computer. After successfully opening it, perform subsequent operations. On this page, set the number of display points of the waveform image, the frequency division number, the waveform data page turning operation, the coefficient setting from waveform data to actual data, whether the waveform is filtered, and whether to display the measurement window.

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