A kind of intermediate shaft yoke swing moment testing system and testing method

Abstract

This invention discloses a system and method for testing the swing torque of an intermediate shaft fork, relating to the field of steering system testing technology. The system includes an industrial computer, a PLC motion controller, a servo motor driver, a data acquisition board, a barcode scanner, a load module, and a MES traceability system. The data acquisition board is used to synchronously acquire torque and angle signals; the PLC motion controller is used to read the product code and control the swing test; the host computer software is used to display the torque-angle variation curve during the swing of the inner and outer forks in real time, and calculates the maximum, minimum, range, and maximum torque fluctuation per 5° after the test, outputting the test results. The product code, test data, and test results are bound and stored in agreed addresses on the industrial computer and PLC respectively for the MES traceability system to read. This invention enables rapid, intuitive, efficient, accurate, and traceable testing of the swing torque of the intermediate shaft fork.

Description

Technical Field

[0001] This invention relates to the field of steering system testing technology, specifically to a system and method for testing the swing torque of an intermediate axle joint fork. Background Technology

[0002] In automotive steering systems, the intermediate shaft is a crucial transmission component connecting the steering input to the steering gear. The swing torque of the inner and outer forks of the intermediate shaft during their swinging process is a vital parameter reflecting the steering system's transmission performance, assembly condition, steering precision, safety, and durability. Therefore, during the development, production testing, and quality control of automotive steering systems, it is typically necessary to test the swing torque of the inner and outer forks of the intermediate shaft to determine whether the product meets the corresponding performance requirements.

[0003] Existing methods for testing the swing torque of intermediate shafts largely rely on manual processes for product identification, parameter setting, test initiation, data acquisition, result analysis, and data recording, resulting in low automation. On one hand, these methods have a slow testing cycle and low efficiency; on the other hand, the large number of manual interventions introduces human error, leading to inconsistent and inaccurate test results, making it difficult to meet the needs of batch and standardized production testing. Especially for scenarios requiring separate testing of the swing torque of the inner and outer intermediate shaft forks, existing methods are often cumbersome, lack intuitiveness, and are not conducive to rapid testing.

[0004] Furthermore, existing testing systems have shortcomings in terms of visualization and data processing during the testing process. Current solutions typically struggle to visually display the relationship between torque and angle during the swing of the inner and outer forks of the intermediate shaft. Operators find it difficult to promptly grasp torque fluctuations during the swing process, and it is also inconvenient to uniformly analyze and determine detection indicators such as maximum, minimum, and range values ​​during clockwise and counterclockwise rotations, as well as torque fluctuations every 5°. This not only affects the intuitiveness and processing efficiency of the test results but also hinders the rapid determination of product qualification.

[0005] Chinese patent document CN202956234U discloses a device for measuring the swing torque of the upper and lower joint forks of the intermediate drive shaft in an automotive steering system. The technical focus of this patent is mainly on the mechanical clamping structure and basic data acquisition and display for swing torque testing. While it can measure the swing torque of the upper and lower joint forks, its disclosure does not reflect the automated testing process based on the collaborative work of an industrial control computer and a PLC motion controller as described in this application. It also does not demonstrate the technical solution of obtaining product codes by scanning barcodes, binding the product codes with the test results after testing, and storing them separately in agreed addresses on the industrial control computer and PLC for the MES traceability system to read. Therefore, it still has shortcomings in terms of testing automation, data processing depth, and production traceability capabilities. Furthermore, patent document CN219265551U discloses a device for detecting the swing torque of the universal joint assembly of the steering drive shaft; this also fails to meet the requirements for fast, intuitive, efficient, accurate, and traceable testing of the swing torque of the inner and outer joint forks of the intermediate shaft.

[0006] Patent document CN203249780U discloses a performance test bench for automotive steering intermediate shaft assembly. Its technical focus is on the overall structure of the intermediate shaft assembly performance test bench and the performance tests of clearance, torsional resistance, etc. However, the disclosed content does not specifically design a phased test process for the swing torque of the inner and outer joint forks of the intermediate shaft, and there are still deficiencies in targeted testing, automatic result judgment, and manufacturing site traceability management.

[0007] In summary, existing technologies still have shortcomings in test data storage and product traceability. When product anomalies occur, if test results cannot be effectively linked to the product's QR code or barcode, or cannot be simultaneously stored locally and in the production traceability system, subsequent location and traceability of problematic products and batches will be difficult, hindering rapid and accurate quality management. Therefore, there is an urgent need for a testing system and method that can quickly, intuitively, efficiently, and accurately test the swing torque of the inner and outer forks of the intermediate shaft, and can link test data to product codes while simultaneously meeting the requirements of local storage and MES traceability. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to overcome the defects of the prior art in the testing of the swing torque of the inner and outer sections of the intermediate shaft, such as low automation, insufficient visualization of the testing process, low efficiency in judging the test results, and difficulty in accurately binding the test data with the product code and making it traceable. The present invention provides a swing torque testing system and method for the intermediate shaft section to achieve fast, intuitive, efficient and accurate testing of the swing torque of the inner and outer sections of the intermediate shaft and traceable management of the test data.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a swing torque testing system for an intermediate shaft joint fork, comprising an industrial control computer, a PLC motion controller, a servo motor driver, a data acquisition board, a barcode scanner, a load module, and a MES traceability system. The industrial control computer is connected to the PLC motion controller via TCP / IP communication, and the PLC motion controller is connected to the servo motor driver. The data acquisition board is installed in the industrial control computer and is connected to a torque sensor and a drive motor encoder for synchronously acquiring torque and angle signals during the swing torque testing process. The load module includes a drive motor, a measured intermediate shaft, a clamping mechanism for holding the measured intermediate shaft, and a torque sensor. The PLC motion controller is used to read the product QR code or product barcode obtained by the barcode scanner. After detecting that the intermediate shaft under test is in place and the clamping mechanism is clamped, it controls the servo motor driver to drive the motor to perform the intermediate shaft swing test, and sends the start acquisition flag signal and the test end flag signal to the industrial control computer. The industrial control computer has a built-in host computer swing torque testing software system. This software system is used to display the torque curves of the inner and outer joints of the tested intermediate shaft swinging with the angle in real time during the test. After the test, the collected data is processed to calculate the maximum, minimum, and range of the clockwise and counterclockwise swinging processes, as well as the maximum torque fluctuation value per 5°. The calculation results are compared with preset limits to obtain the test results. The product code, test data, and test results are bound together to form a test record. One test record is stored in the industrial control computer's set path, and the other test record is written to the PLC's agreed address for the MES traceability system to read.

[0010] Furthermore, the data acquisition board has the functions of multi-channel analog signal acquisition, digital IO signal acquisition and pulse counting, so as to realize torque signal acquisition, status signal acquisition and swing angle acquisition respectively.

[0011] Furthermore, the host computer swing torque testing software system includes a user login module, a parameter setting module, a calibration parameter setting module, a sampling setting module, an alarm information module, a user help module, and a data display processing and storage module.

[0012] Furthermore, the parameter setting module is used to set the test result storage path, parameter configuration storage path, parameter file selection, product model, test pass upper and lower limits, and range judgment value, and supports the storage and retrieval of parameter files for different product models.

[0013] Furthermore, the calibration parameter setting module is used to verify whether the torque sensor measurement value matches the actual torque value, and to perform calibration when there is a deviation; the sampling setting module is used to set the sampling rate and number of sampling points of the data acquisition board.

[0014] Furthermore, the data display processing and storage module is used to display the inner fork swing test curve and the outer fork swing test curve in different colors on the main test page, and to display the corresponding detection values ​​and test results after the test is completed.

[0015] Furthermore, the MES traceability system achieves test data traceability by reading the detection records at a predetermined address in the PLC motion controller; the detection records include at least the product code, test time, product model, detection value, and test result of whether the test is qualified or not.

[0016] Furthermore, the testing system is configured as a single-station structure or a multi-station structure; in the multi-station structure, each station displays the corresponding test curve and test results, and can simultaneously perform swing torque tests on different product models.

[0017] Furthermore, the present invention also provides a testing method based on the above-mentioned intermediate axle joint fork swing torque testing system, comprising the following steps: S1. The user logs into the host computer swing torque testing software system; S2. In the parameter configuration page, set the test result storage path, parameter configuration storage path, test pass upper and lower limits, range judgment value, and corresponding product model parameters; S3. The PLC motion controller reads the product QR code or product barcode obtained by the barcode scanner and stores the product code in the agreed address. After detecting that the intermediate shaft under test is in place and the clamping mechanism is clamped, the swing torque test is started, and a start acquisition flag signal is sent to the industrial control computer through the change of the flag signal bit. After the test is completed, a test end flag signal is sent to the industrial control computer through the change of the flag signal bit. After the test is completed, the PLC motion controller sends a test end flag signal to the industrial control computer through the change of the flag signal bit to trigger the industrial control computer to perform background data processing.

[0018] S4. After receiving the start acquisition flag signal, the industrial control computer synchronously acquires torque and angle signals through the data acquisition board and displays the torque-angle change curve during the swing of the tested intermediate shaft in real time on the host computer's test main page; the inner fork swing test curve and the outer fork swing test curve are displayed in different colors in real time on the software main page according to their order. S5. After the test, the industrial control computer processes the collected data, calculates the maximum value, minimum value, range and the maximum torque fluctuation value per 5° during the clockwise and counterclockwise oscillation process, and compares the calculation results with the preset limit to obtain the test results. S6. The industrial control computer binds the product code, test data and test results to form a test record, and stores one copy of the test record in a set path and writes another copy to the PLC's agreed address for the MES traceability system to read.

[0019] Furthermore, step S5, calculating the maximum torque fluctuation per 5°, includes: The array of torque versus angle curves collected during the swing process is unbound into an angle array and a torque array, and then the angle array and torque array are bound one by one according to the index correspondence. The bound data is traversed, and data that meets the condition of clockwise torque being greater than 0 are selected and combined to form a two-dimensional array in which the angle and torque correspond one-to-one. The number of traversals N is obtained by dividing the swing angle range by a set degree of 5, and the two-dimensional array is traversed according to the 5° interval to obtain the difference array formed by the difference between the maximum torque value and the minimum torque value in each 5° interval. The maximum value in the difference array is obtained as the maximum torque fluctuation per 5° during the oscillation process.

[0020] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention, through the coordinated operation of an industrial control computer, a PLC motion controller, a servo motor driver, a data acquisition board, and a load module, achieves automated processing of product barcode scanning and identification, swing test initiation, torque and angle signal acquisition, test result output, and data storage. This reduces the reliance on manual identification, recording, and judgment in existing technologies, thereby effectively reducing human error and improving the efficiency, stability, and consistency of swing torque testing of the inner and outer forks of the intermediate shaft. It is more suitable for continuous and batch testing applications in production sites.

[0021] 2. This invention can perform phased swing tests on the inner and outer joints of the intermediate shaft, and display the torque versus angle curve in real time on the host computer main page in different colors. This allows the operator to intuitively observe the torque changes throughout the swing process and promptly detect abnormal torque fluctuations or phase deviations. Compared with existing technologies that mainly focus on mechanical clamping or basic torque detection, this invention is more targeted at the swing torque detection scenario of the inner and outer joints of the intermediate shaft, and can significantly improve the real-time performance, visualization, and intuitiveness of the test results.

[0022] 3. After the test, this invention can process the collected torque and angle signals in the background, automatically calculate the maximum, minimum, and range values ​​during clockwise and counterclockwise oscillations, as well as the maximum torque fluctuation value per 5°, and compare each measured value with preset limits to output the test result indicating whether it is qualified or not. This standardizes, proceduralizes, and unifies the previously fragmented or manual analysis-dependent testing and evaluation process, improving the objectivity, accuracy, and processing efficiency of the test results, and facilitating the rapid completion of intermediate shaft oscillation torque detection and quality assessment.

[0023] 4. This invention reads the product's QR code or barcode using a barcode scanner and binds the product code with test data and test results to form a test record. One copy is stored in a set path on the industrial control computer, and the other is written to a designated address on the PLC for the MES traceability system to retrieve and store. This achieves a precise "one item, one code" correspondence and a dual error prevention mechanism combining local storage and the traceability system. Simultaneously, this invention also supports parameter file storage and readback, and can be expanded into a single-station or multi-station testing structure. Therefore, it not only significantly improves product quality traceability capabilities and reduces the cost of locating problematic batches and after-sales recalls, but also has good compatibility and scalability, adapting to the testing needs of different models of intermediate shafts and different production cycles. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the hardware architecture of the present invention; Figure 2 This is a schematic diagram of the testing process of the present invention; Figure 3 This is a schematic diagram of the test main page of the present invention; Figure 4 This is a schematic diagram showing the curves of the swing torque of the inner and outer joint forks of the intermediate shaft as a function of angle, collected and measured according to the present invention. Figure 5 A schematic diagram of some test data captured by the MES traceability system; Figure 6 This is a diagram illustrating the data stored in the background after the industrial control computer has completed testing. Detailed Implementation

[0025] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention; Example 1: Intermediate Shaft Joint Fork Swing Torque Testing System like Figure 1 As shown, this embodiment provides a swing torque testing system for intermediate shaft forks, including an industrial control computer, a PLC motion controller, a servo motor driver, a data acquisition board, a barcode scanner, a load module, and a MES traceability system. The industrial control computer is connected to the PLC motion controller via TCP / IP communication, and the PLC motion controller is connected to the servo motor driver. The data acquisition board is located in the industrial control computer and is connected to the torque sensor and the drive motor encoder, respectively, for synchronously acquiring torque and angle signals during the swing torque testing process. The load module includes a drive motor, the intermediate shaft under test, a clamping mechanism for holding the intermediate shaft under test, and a torque sensor. Through the above structural configuration, automatic testing, real-time display, background processing, and result traceability of the swing torque of the inner and outer forks of the intermediate shaft under test are realized.

[0026] In this embodiment, the industrial control computer (ICC) has a built-in host computer swing torque testing software system and a data acquisition board. The ICC receives the start acquisition flag signal, the test end flag signal, and the product code information sent by the PLC motion controller, and completes the acquisition, display, processing, result judgment, and storage of test data. The PLC motion controller receives product positioning information and barcode scanning information, and after detecting that the intermediate shaft under test is in position and the clamping mechanism is clamped, it controls the servo motor driver to drive the drive motor to perform the swing test. The ICC sends a start acquisition flag signal to the ICC at the start of the test and a test end flag signal to the ICC at the end of the test. The MES traceability system communicates with the PLC motion controller and realizes the traceability of test results by reading the detection records in the PLC's agreed address.

[0027] In this embodiment, the PLC motion controller can be a Siemens S7-1200 series controller, the servo motor driver can be a Siemens V90 series driver, the data acquisition board can be a Jianyi PCIe5111 data acquisition card, and the barcode scanner can be a Keyence barcode scanner. The above device models are only preferred examples and do not limit the present invention to using the specific models mentioned above. As long as the same control, acquisition, and identification functions can be achieved, they can be used to implement the present invention. The data acquisition board has multiple analog signal acquisition, digital IO signal acquisition, and pulse counting functions. The analog signal acquisition channel is used to acquire the analog voltage signal output by the torque sensor, the pulse counting function is used to acquire the angle signal fed back by the encoder of the drive motor, and the digital IO acquisition function is used to acquire the status signal so as to achieve synchronous acquisition of torque signal and angle signal.

[0028] The load module is used to complete the actual swing torque test. The drive motor is connected to one end of the intermediate shaft under test, the clamping mechanism is used to clamp the intermediate shaft under test, and the torque sensor is set in the drive link to obtain the torque information generated during the swing. During the test, the clamping mechanism first clamps one side of the intermediate shaft under test, and the drive motor drives the intermediate shaft under test to swing, completing the first stage of the swing torque test. Then the clamping mechanism rotates 90° and swings again to complete the second stage of the swing torque test. Through the above two stages of test, the torque-angle relationship data of the outer and inner forks of the intermediate shaft under test during the swing process can be obtained respectively.

[0029] Example 2: Host Computer Swing Torque Testing Software System In this embodiment, the industrial control computer has a built-in host computer swing torque testing software system; the host computer swing torque testing software system includes a user login module, a parameter setting module, a calibration parameter setting module, a sampling setting module, an alarm information module, a user help module, and a data display processing and storage module; the above modules can be implemented by the host computer software in the industrial control computer, preferably developed based on a graphical programming environment or an industrial control software platform.

[0030] The user login module is used to authenticate and manage permissions for users entering the testing system. Preferably, three permission levels can be set: debugging personnel, administrators, and ordinary users. Debugging personnel have higher permissions and can perform menu operations and modify parameters on the main page. Administrators can access the parameter configuration page to modify test parameters. Ordinary users can view the test page after entering the system, and if they need to modify configuration parameters, they need to enter their password again for permission verification. This method can reduce the impact of unauthorized modifications on test results.

[0031] The parameter setting module is used to set parameters such as the test result storage path, parameter configuration storage path, parameter file selection, product model, test pass and fail limits, and range judgment value. It also supports storing and retrieving parameter files for different product models. In actual use, users can select the test parameters corresponding to different product models on the parameter configuration page to adapt to the testing needs of different vehicle models and intermediate shafts of different specifications. The configuration parameters may include, but are not limited to, the maximum value, minimum value, range, maximum torque fluctuation per 5°, and upper and lower limits of the swing angle during clockwise and counterclockwise swing.

[0032] The calibration parameter setting module is used to verify whether the torque sensor measurement value matches the actual torque value; when there is a deviation, calibration is performed through this module to ensure the accuracy of torque measurement; the sampling setting module is used to set the sampling rate and number of sampling points of the data acquisition board to adapt to different test cycles and different test accuracy requirements; the alarm information module is used to display the cause of alarms generated during the operation of the test system and can realize alarm reset; the user help module is used to retrieve the software user manual so that operators can quickly master the software operation.

[0033] The data display processing and storage module is used to display the collected swing test curves of the inner and outer joints of the intermediate shaft in different colors on the main test page during the test, and to display the corresponding detection values ​​and test results after the test. Preferably, the swing test curve of the outer joint in the first stage is displayed in blue, and the swing test curve of the inner joint in the second stage is displayed in red. Of course, other distinguishable colors can also be used for display, as long as they can achieve intuitive differentiation between the two test curves. After the test, the display module can also display the maximum value, minimum value, range, and maximum torque fluctuation value per 5° during the clockwise and counterclockwise swing process on the main page, and display the judgment result of whether it is qualified or not.

[0034] Example 3: Test method for swing torque of intermediate shaft joint fork like Figure 2 As shown, this embodiment provides a method for testing the swing torque of the intermediate axle joint fork based on the above-described testing system, including the following steps: Step S1: User login.

[0035] Users log in to the host computer swing torque testing software system, enter the corresponding username and password to enter the software's main page; depending on the permission level, users can perform different ranges of operations, including viewing the test interface, selecting product parameter files, modifying test thresholds, setting storage paths, etc.

[0036] Step S2: Parameter configuration.

[0037] On the parameter configuration page, users can set the test result storage path, parameter configuration storage path, test pass and fail limits, range judgment value, and corresponding product model parameters. If the system already has the parameter file corresponding to the model, the configuration file can be read back directly to improve the efficiency of model changeover. The set parameters can be used for subsequent test result judgment and data storage.

[0038] Step S3: Product identification and test preparation.

[0039] The PLC motion controller reads the product QR code or product barcode obtained by the barcode scanner and stores the product code in a predetermined address. Preferably, after the barcode scanner reads the product QR code, the planned address in the PLC can undergo a rising edge change from 0 to 1. The host computer captures this change in real time and reads the product code. After reading the product code, the system waits for the intermediate shaft under test to be placed in position. When the PLC detects that the intermediate shaft under test is in position and the clamping mechanism is clamped, the PLC motion controller starts the swing torque test and sends a start acquisition flag signal to the industrial control computer. After the test is completed, the PLC motion controller sends a test end flag signal to the industrial control computer through a change in the flag signal bit to trigger the industrial control computer to perform background data processing.

[0040] Step S4: Real-time data acquisition and curve display.

[0041] After receiving the start acquisition signal, the industrial control computer synchronously acquires torque and angle signals through the data acquisition board and displays the torque-angle change curve during the swing of the tested intermediate shaft on the host computer's test main page in real time. Preferably, the test is divided into two stages: the first stage is the outer fork swing test. After the clamping mechanism clamps one side of the tested intermediate shaft, it starts to swing, and the outer fork test curve is displayed in blue on the software main page. After the first stage ends, the clamping mechanism rotates 90° to start the second stage, the inner fork swing test, and the inner fork test curve is displayed in red on the software main page. Through the above sequence and different colors, the operator can intuitively distinguish the swing test processes of the inner and outer forks.

[0042] Step S5: Backend data processing and result determination.

[0043] After the test, the industrial control computer processes the collected data, calculates the maximum, minimum, and range values ​​during clockwise and counterclockwise oscillations, as well as the maximum torque fluctuation value per 5°, and compares the calculation results with preset limits to obtain the test results. In addition to calculating the above key detection values, it can also calculate other statistical indicators related to oscillation torque as needed. The industrial control computer displays the calculation results and the product qualification / disqualification results on the main page. At the same time, the industrial control computer can send qualified or unqualified signals to the PLC motion controller. When the product is determined to be unqualified, the PLC motion controller can control the clamping mechanism to send the intermediate shaft under test into the defective product channel.

[0044] Step S6: Detect record binding and dual storage.

[0045] The industrial control computer binds product codes, test data, and test results to form a test record. One copy of the test record is stored in a designated path, and the other copy is written to a designated address in the PLC for the MES traceability system to read. By storing the test record locally on the industrial control computer and in the designated address in the PLC, a dual error prevention mechanism can be formed, and the precise correspondence of "one item, one code" can be achieved. The MES traceability system can trace the test time, product model, test value, and pass / fail test results by reading the test record at the designated address in the PLC motion controller.

[0046] Example 4: Calculation method for the maximum torque fluctuation per 5° This embodiment further explains the calculation process of the maximum torque fluctuation value every 5° in step S5; this calculation method is based on the torque-angle curve data collected synchronously during the test; preferably, it can be implemented according to the following process: First, the array of torque versus angle curves collected during the oscillation process is unbound into an angle array and a torque array. Then, the angle array and torque array are bound one-to-one according to the index correspondence, forming a data set where angle and torque correspond one-to-one. Since the torque is positive during clockwise oscillation, the bound data is traversed to filter out the data that meets the condition that clockwise torque is greater than 0, and combined to form a two-dimensional array where angle and torque correspond one-to-one. If it is necessary to calculate the counterclockwise process, the data that meets the condition that torque is less than 0 is filtered out. Then, the number of iterations N is obtained by dividing the swing angle range by the set degree of 5°, and the two-dimensional array is traversed according to the 5° intervals. Specifically, the minimum value MIN in the angle array is taken as the swing starting angle, the number of iterations of the outer For loop is N, the loop index is i, and the value of i ranges from 0 to N-1; the lower limit of the angle interval corresponding to the i-th iteration is MIN+i×5°, and the upper limit is MIN+(i+1)×5°; within each 5° interval, the maximum and minimum torque values ​​are calculated, and the difference between the two is calculated to obtain the torque fluctuation value within that interval; after all intervals are processed, a difference array composed of the torque fluctuation values ​​of each 5° interval is obtained; then the maximum value is taken from this difference array as the maximum torque fluctuation value for each 5° interval during the swing process; Using the above method, not only can the maximum torque fluctuation value per 5° be calculated, but also the maximum, minimum, and range values ​​can be obtained in the same data processing flow. This method can program and standardize the torque fluctuation analysis process that originally relied on manual judgment, thereby improving the objectivity, consistency, and processing efficiency of the test results.

[0047] Example 5: Multi-station testing implementation method like Figure 3As shown, the testing system of the present invention can also be configured as a single-station structure or a multi-station structure. In the multi-station structure, each station displays the corresponding test curve and test results, and can simultaneously perform swing torque tests on different product models. Preferably, the main software page can simultaneously display the real-time test interface of multiple stations, and each station can independently read the corresponding product code, call the corresponding model parameter file, complete the test, process the data, and display the results. The multi-station structure is suitable for mass production sites and can improve the overall testing efficiency without changing the basic control logic and data processing logic of the present invention.

[0048] Example 6: Explanation of the corresponding figures like Figure 4 The figure shows the curves of the swing torque of the inner and outer joints of the intermediate shaft as a function of angle, which were collected and measured by the present invention. The curves of different colors correspond to the swing test process of the outer and inner joints, respectively. The operator can intuitively observe the torque fluctuation or phase deviation during the test process based on the curve shape.

[0049] like Figure 5 The image shown is a partial display of the test data captured by the MES traceability system. The MES traceability system reads the detection records in the PLC's agreed address and displays the test data and test results corresponding to the product code.

[0050] like Figure 6 The image shown is a display of the data stored in the background after the industrial control computer test is completed. The test record preferably includes the test time, product model, product code, various test values, and the final judgment result. Figure 5 and Figure 6 The dual-storage method shown enables quality error prevention and batch traceability by combining local storage with MES traceability.

[0051] The foregoing has shown and described the basic principles, main features and advantages of the present invention. Various changes and modifications can be made to the present invention without departing from the spirit and scope thereof, and all such changes and modifications fall within the scope of the present invention as claimed.

Claims

1. A system for testing the swing torque of an intermediate shaft joint fork, comprising an industrial computer, a PLC motion controller, a servo motor driver, a data acquisition board, a barcode scanner, a load module, and an MES traceability system, characterized in that: The industrial computer is connected to the PLC motion controller via TCP / IP communication, and the PLC motion controller is connected to the servo motor driver. The data acquisition board is installed in the industrial computer and is connected to the torque sensor and the drive motor encoder to synchronously acquire torque and angle signals during the swing torque test. The load module includes a drive motor, a measured intermediate shaft, a clamping mechanism for holding the measured intermediate shaft, and a torque sensor. The PLC motion controller is used to read the product QR code or product barcode obtained by the barcode scanner. After detecting that the intermediate shaft under test is in place and the clamping mechanism is clamped, it controls the servo motor driver to drive the motor to perform the intermediate shaft swing test, and sends the start acquisition flag signal and the test end flag signal to the industrial control computer. The industrial control computer has a built-in host computer swing torque testing software system. This software system is used to display the torque curves of the inner and outer joints of the tested intermediate shaft swinging with the angle in real time during the test. After the test, the collected data is processed to calculate the maximum, minimum, and range of the clockwise and counterclockwise swinging processes, as well as the maximum torque fluctuation value per 5°. The calculation results are compared with preset limits to obtain the test results. The product code, test data, and test results are bound together to form a test record. One test record is stored in the industrial control computer's set path, and the other test record is written to the PLC's agreed address for the MES traceability system to read.

2. The intermediate shaft joint fork swing torque testing system according to claim 1, characterized in that: The data acquisition board has the functions of multi-channel analog signal acquisition, digital IO signal acquisition and pulse counting, so as to realize torque signal acquisition, status signal acquisition and swing angle acquisition respectively.

3. The intermediate shaft joint fork swing torque testing system according to claim 1, characterized in that: The host computer swing torque testing software system includes a user login module, a parameter setting module, a calibration parameter setting module, a sampling setting module, an alarm information module, a user help module, and a data display processing and storage module.

4. The intermediate shaft joint fork swing torque testing system according to claim 3, characterized in that: The parameter setting module is used to set the test result storage path, parameter configuration storage path, parameter file selection, product model, test pass upper and lower limits, and range judgment value, and supports the storage and retrieval of parameter files for different product models.

5. The intermediate shaft joint fork swing torque testing system according to claim 3, characterized in that: The calibration parameter setting module is used to verify whether the torque sensor measurement value matches the actual torque value, and to perform calibration when there is a deviation; the sampling setting module is used to set the sampling rate and number of sampling points of the data acquisition board.

6. The intermediate shaft joint fork swing torque testing system according to claim 1, characterized in that: The data display processing and storage module is used to display the inner fork swing test curve and the outer fork swing test curve in different colors on the main test page, and to display the corresponding detection values ​​and test results after the test is completed.

7. The intermediate shaft joint fork swing torque testing system according to claim 1, characterized in that: The MES traceability system achieves test data traceability by reading the detection records at a predetermined address in the PLC motion controller; the detection records include at least the product code, test time, product model, test value, and test result of whether the test is qualified or not.

8. The intermediate shaft joint fork swing torque testing system according to claim 1, characterized in that: The testing system is configured as a single-station structure or a multi-station structure; in the multi-station structure, each station displays the corresponding test curve and test results, and can simultaneously perform swing torque tests on different product models.

9. A test method based on the intermediate axle joint fork swing torque test system according to any one of claims 1 to 8, characterized in that, Includes the following steps: S1. The user logs into the host computer swing torque testing software system; S2. In the parameter configuration page, set the test result storage path, parameter configuration storage path, test pass upper and lower limits, range judgment value, and corresponding product model parameters; S3, the PLC motion controller reads the product QR code or product barcode obtained by the barcode scanner and stores the product code in the agreed address; after detecting that the intermediate shaft under test is in place and the clamping mechanism is clamped, the swing torque test is started, and a start acquisition flag signal is sent to the industrial control computer through the change of the flag signal bit; after the test is completed, a test end flag signal is sent to the industrial control computer through the change of the flag signal bit; after the test is completed, the PLC motion controller sends a test end flag signal to the industrial control computer through the change of the flag signal bit to trigger the industrial control computer to perform background data processing; S4. After receiving the start acquisition flag signal, the industrial control computer synchronously acquires torque and angle signals through the data acquisition board and displays the torque-angle change curve during the swing of the tested intermediate shaft in real time on the host computer's test main page; the inner fork swing test curve and the outer fork swing test curve are displayed in different colors in real time on the software main page according to their order. S5. After the test, the industrial control computer processes the collected data, calculates the maximum value, minimum value, range and maximum torque fluctuation per 5° during the clockwise and counterclockwise oscillation process, and compares the calculation results with the preset limit to obtain the test results. S6. The industrial control computer binds the product code, test data and test results to form a test record, and stores one copy of the test record in a set path and writes another copy to the PLC's agreed address for the MES traceability system to read.

10. The test method according to claim 9, characterized in that: Step S5, which calculates the maximum torque fluctuation every 5°, includes: The array of torque versus angle curves collected during the swing process is unbound into an angle array and a torque array, and then the angle array and torque array are bound one by one according to the index correspondence. The bound data is traversed, and data that meets the condition of clockwise torque being greater than 0 are selected and combined to form a two-dimensional array in which the angle and torque correspond one-to-one. The number of traversals N is obtained by dividing the swing angle range by a set degree of 5, and the two-dimensional array is traversed according to the 5° interval to obtain the difference array formed by the difference between the maximum torque value and the minimum torque value in each 5° interval. The maximum value in the difference array is obtained as the maximum torque fluctuation per 5° during the oscillation process.

Images