A testing device and method for an electronically controlled transfer case shift actuator.

Abstract

This invention belongs to the technical field of automotive electronic transfer cases, and relates to a detection device and method for the shift actuator of an electronic transfer case. The detection device for the shift actuator includes a detection positioning unit and a data acquisition unit. The resolver rotor shaft of the rotary transformer in the detection positioning unit is connected to the first output hole of the shift actuator, so that the encoder and the resolver rotor rotate coaxially. The rotary transformer is used to detect the detection mechanical angle distribution information of each encoder code. By comparing the detection mechanical angle distribution information of the encoder with the design mechanical angle distribution information of the encoder, it is determined whether the mechanical angle range detected by each code meets the design requirements, thereby achieving accurate detection of the rotation angle range of the shift mechanism output end corresponding to each code value of the encoder of the electronic transfer case shift actuator.

Description

Technical Field

[0001] This invention belongs to the field of automotive electronic transfer case technology, and relates to a testing device and testing method for the shift actuator of an electronic transfer case. Background Technology

[0002] A transfer case is a device for distributing power in a car, widely used in off-road vehicles. With increasing demands for driving comfort, mechanical transfer cases operated by levers are gradually being phased out, and electronically controlled transfer cases are becoming increasingly common.

[0003] The shift actuator on the electronically controlled transfer case is one of the main components that enables electronic shifting. It consists of a drive motor, a gearbox, and an encoder. Their functions are as follows: the drive motor is the power source; the gearbox reduces speed and increases torque and outputs power, and is connected to the transfer case shift shaft; the encoder provides feedback on the gear position signal.

[0004] The encoder's encoding position, the mechanical angle between each encoder, and the angle range must be consistent with the angle between each gear in the transfer case. If there is a large error in these angles, it may cause the gear to fail to shift or to disengage.

[0005] To non-destructively test the accuracy of the coding angles, it is generally necessary to install and run the equipment, and determine the quality of the shift actuator by testing the output of the transfer case. This type of testing cannot detect the angles between all codings, the coding positions, or the angle range of each coding. If a coding error occurs in the middle, it will also lead to control errors and prevent shifting. Summary of the Invention

[0006] To address the above problems, this invention provides a detection device for an electronically controlled transfer case shifting actuator. This device can accurately detect the mechanical angle position and range corresponding to each code of the encoder of the electronically controlled transfer case shifting actuator. It has high detection accuracy, good stability, strong anti-interference ability, simple structure, and is easy to promote and popularize.

[0007] The technical solution adopted in this invention is a detection device for the shifting actuator of an electronically controlled transfer case, comprising a detection and positioning unit and a data acquisition unit;

[0008] The detection and positioning unit includes a rotary transformer and a base plate. The rotary transformer is integrally mounted on the bottom surface of the base plate. The rotary transformer includes a resolver rotor shaft. The base plate includes a through hole, a mating surface, and a positioning pin. The mating surface is located on the upper surface of the base plate and is used to mat with the lower surface of the electronically controlled transfer case shifting actuator with an encoder. The first end face of the resolver rotor shaft passes through the through hole. A triangular boss is provided on the first end face. The triangular boss is used to match and connect with the first output hole of the electronically controlled transfer case shifting actuator. The triangular boss is in the shape of an isosceles triangle, which is not an equilateral triangle. The positioning pin is provided on the mating surface and is used to match and connect with any shift motor positioning hole on the base plate of the electronically controlled transfer case shifting actuator.

[0009] The data acquisition unit is used to acquire the encoded value information output by the encoder and the rotation electrical angle information output by the rotary transformer.

[0010] Furthermore, the electronically controlled transfer case shifting actuator also includes a calibration fixture, which has a triangular hole that matches the triangular boss and a mounting hole that matches the positioning pin.

[0011] Furthermore, the calibration fixture is used to calibrate the detection zero position of the rotary transformer, so that the electronically controlled transfer case shifting actuator is installed on the detection positioning unit, the triangular boss is connected to the first output hole, the positioning pin is connected to the first shifting motor positioning hole on the base plate of the electronically controlled transfer case shifting actuator, and then the electronically controlled transfer case shifting actuator is driven to rotate so that the rotary transformer returns to the detection zero position. The code corresponding to the detection zero position at this time and its position in the code should be consistent with the first design position on the encoder's code disk.

[0012] Based on the detection device for the shift actuator of an electronically controlled transfer case provided by the present invention, the present invention also provides a detection method for the shift actuator of an electronically controlled transfer case, the method comprising the following steps:

[0013] Step 1: Zero-point calibration of the rotary transformer;

[0014] Step 2: Based on the encoded value information and rotational electrical angle information collected by the data acquisition unit, a mapping relationship is formed between the electrical angle position in the rotary transformer and each code on the encoder disk, and the electrical angle position of the detection zero point in the rotary transformer is obtained.

[0015] Step 3: The detection device is used to detect the position of the detection zero point on the encoder's code disk corresponding to the mapping relationship. Then, the design mechanical angle distribution information of each code in the encoder is obtained through the code disk encoding distribution design of the encoder.

[0016] Step 4: Using the detection device, starting from the detection zero position, perform detection to obtain the detection mechanical angle distribution information of each of the codes in the encoder;

[0017] Step 5: Compare the designed mechanical angle distribution information with the detected mechanical angle distribution information; determine whether the mechanical angle range of each code meets the design requirements based on the comparison results.

[0018] Furthermore, the method for calibrating the zero position of the rotary transformer in step 1 includes: installing the electronically controlled transfer case shifting actuator on the detection and positioning unit, connecting the triangular boss to the first output hole, connecting the positioning pin to any shifting motor positioning hole, and taking the electrical angle position in the rotary transformer at this time as the zero position of the rotary transformer.

[0019] Furthermore, the specific implementation method of step 2 includes: installing the electronically controlled transfer case shifting actuator on the detection and positioning unit, connecting the triangular boss to the first output hole, connecting the positioning pin to any shifting motor positioning hole, taking any electrical zero position of the rotary transformer as the starting point, sequentially numbering each resolver sector of the rotary transformer according to the forward rotation direction of the rotary transformer, and making the electrical angle position in the rotary transformer and each of the codes on the encoder disk form a mapping relationship according to the encoding value information and rotation electrical angle information collected by the data acquisition unit, setting the detection zero position in any numbered resolver sector, and obtaining the electrical angle position of the detection zero position in the rotary transformer according to the rotation electrical angle information collected by the data acquisition unit.

[0020] Furthermore, the specific implementation method of step 3 includes: taking the position of the detection zero point detected by the detection device and corresponding to the code disk through the mapping relationship as the first actual position, finding the position of the first actual position in the code disk encoding distribution design, and then taking any electrical zero point of the rotary transformer as the mechanical zero point of the encoder to obtain the mechanical angle position of the first actual position in the encoder, and then obtaining the design mechanical angle distribution information of each code in the encoder through the code disk encoding distribution design.

[0021] Furthermore, the method for calibrating the zero position of the rotary transformer in step 1 includes: installing the calibration fixture on the detection positioning unit, connecting the triangular hole on the calibration fixture to the triangular boss, connecting the mounting hole on the calibration fixture to the positioning pin, and taking the electrical angle position in the rotary transformer at this time as the zero position of the rotary transformer.

[0022] The specific implementation of step 2 includes: taking any electrical zero point of the rotary transformer as the starting point, numbering each sector of the rotary transformer sequentially according to the forward rotation direction of the rotary transformer, setting the detection zero point in any numbered sector, and obtaining the electrical angle position of the detection zero point in the rotary transformer based on the rotational electrical angle information collected by the data acquisition unit; then removing the calibration fixture, installing the electronically controlled transfer case shifting actuator on the detection positioning unit, connecting the triangular boss to the first output hole, and connecting the positioning pin to the first shifting motor positioning hole, wherein the first shifting motor positioning hole is a specific shifting motor positioning hole; and, based on the encoded value information and rotational electrical angle information collected by the data acquisition unit, making the electrical angle position in the rotary transformer and each of the codes on the encoder's code disk form a mapping relationship.

[0023] The specific implementation of step 3 includes: driving the electronically controlled transfer case shifting actuator to rotate so that the rotary transformer returns to the detection zero position; detecting the detection zero position through the detection device to obtain the position on the code disk corresponding to the mapping relationship as the first actual position; then adjusting the installation angle of the encoder on the electronically controlled transfer case shifting actuator to adjust the first actual position to the first designed position on the code disk so that the installation angle of the encoder on the electronically controlled transfer case shifting actuator meets the design requirements; finding the position corresponding to the first actual position in the code disk encoding distribution design; then obtaining the mechanical angle position of the first actual position in the encoder by taking any electrical zero position of the rotary transformer as the mechanical zero position of the encoder; and finally obtaining the designed mechanical angle distribution information of each code in the encoder through the code disk encoding distribution design.

[0024] Furthermore, in step 3, the first design position is located in the non-blocking area of ​​the code disk, and the first design position is the middle position of any of the codes or the boundary of adjacent codes.

[0025] Furthermore, in step 3, the specific implementation method of obtaining the position of the detection zero point on the code disk corresponding to the mapping relationship as the first actual position by the detection device includes: acquiring the encoding value output by the encoder at the detection zero point through the data acquisition unit to obtain the encoding corresponding to the detection zero point through the mapping relationship; then, taking the detection zero point as the starting point, the electronically controlled transfer case shifting actuator rotates forward and reverse to the first change point of the encoding value of the encoding, respectively, and measuring the positive offset electrical angle and the negative offset electrical angle relative to the detection zero point, thereby obtaining the encoding corresponding to the first actual position and the positive offset mechanical angle and the negative offset mechanical angle of the two ends of the encoding relative to the first actual position, that is, obtaining the current position of the first actual position on the code disk. Attached Figure Description

[0026] Figure 1 This is a three-dimensional structural diagram of the electronically controlled transfer case shifting mechanism in this embodiment;

[0027] Figure 2 This is a front view of the electronically controlled transfer case shifting mechanism in this embodiment;

[0028] Figure 3 This is a bottom view of the electronically controlled transfer case shifting mechanism in this embodiment;

[0029] Figure 4 This is a top view of the electronically controlled transfer case shift actuator after the encoder has been removed in this embodiment;

[0030] Figure 5 This is a front view of the encoder in this embodiment;

[0031] Figure 6 This is a bottom view of the encoder in this embodiment;

[0032] Figure 7 This is a diagram showing the encoder's code disk encoding distribution design in this embodiment;

[0033] Figure 8 This is a front view of the detection and positioning unit in this embodiment;

[0034] Figure 9 This is a schematic diagram of the assembly structure of the detection device and the electronically controlled transfer case shifting actuator in this embodiment;

[0035] Figure 10 This is a schematic diagram of the bonding surface on the substrate in this embodiment;

[0036] Figure 11 This is a top view of the calibration fixture in this embodiment;

[0037] Figure 12 This is a diagram showing the position of the first design location on the code disk in this embodiment;

[0038] Figure 13 This is a mapping diagram of the encoder's code disk encoding and the electrical angle position in the resolver in this embodiment.

[0039] Figure 14 A table showing the code-angle correspondence for the actual testing of the gear shifting actuator;

[0040] Wherein: 1—Electrically controlled transfer case shifting mechanism;

[0041] 11—Encoder, 12—Drive motor, 13—Reduction gearbox, 14—First output hole, 15—First shift motor positioning hole, 16—Second output hole;

[0042] 111—Encoder output shaft;

[0043] 2—Detection and positioning unit;

[0044] 21—Resolver; 22—Substrate;

[0045] 211—Resolver stator, 212—Resolver rotor, 213—Resolver rotor shaft, 214—Resolver stator fixing plate, 215—Resolver rotor fixing plate, 216—Slewing bearing, 217—Triangular boss;

[0046] 221—Through hole, 222—Mating surface, 223—Positioning pin;

[0047] 3—Data acquisition unit;

[0048] 31—Signal output component for gear shifting mechanism; 32—Signal output component for resolver;

[0049] 4—Calibration fixtures;

[0050] 41—Triangular hole, 42—Mounting hole. Detailed Implementation

[0051] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0052] This invention proposes an embodiment of a detection device and method for a gear shifting actuator. Based on the angle range measurement achieved by the encoder 11 built into the gear shifting actuator 1 of the electronically controlled transfer case, the precise electrical angle output by the rotary transformer 21 on the detection device of the gear shifting actuator of the electronically controlled transfer case is used. The two are combined to achieve precise measurement of the mechanical angular position of each code in the encoder 11.

[0053] like Figures 1-4 As shown, in this embodiment, the electronically controlled transfer case shifting actuator 1 includes an encoder 11, a drive motor 12, a reduction gearbox 13, a first output port 14, a first shift motor positioning port 15, and a second output port 16. Their functions are as follows: the drive motor 12 is a power source, and after being reduced in speed and increased in torque by the reduction gearbox 13, the power is output through the first output port 14 and the second output port 16 located at the upper and lower ends of the reduction gearbox 13, respectively. The bottom of the reduction gearbox 13 of the electronically controlled transfer case shifting actuator 1 is provided with a plurality of shift motor positioning ports, and one of the specific shift motor positioning ports is designated as the first shift motor positioning port 15.

[0054] In this embodiment, the first output hole 14 is an isosceles triangle shape that is not an equilateral triangle, and the rotation center of the first output hole 14 intersects the angle bisector of the vertex of the isosceles triangle, so that the vertex of the isosceles triangle of the first output hole 14 has a pointing function. Since the first output hole 14 has a pointing function, the pointing direction of the vertex of the first output hole 14 also has a corresponding relationship with the mechanical angle position of the encoder 11.

[0055] like Figure 4 — Figure 6 As shown, in this embodiment, the encoder 11 is connected to the second output hole 16 via the encoder output shaft 111 located at the center of its bottom surface, realizing coaxial transmission between the encoder output shaft 111 and the output end of the gearbox 13. That is, the encoder output shaft 111 and the output end of the gearbox 13 rotate in the same direction and at the same angular velocity. Therefore, the angular velocity of the apex of the first output hole 14 is the same as the angular velocity of the encoder 11. At the same time, since the positions of each encoder 11 are consistent with the positions of each gear of the electronic transfer case shifting mechanism 1, the mechanical angle between each encoder is consistent with the mechanical angle between each gear of the electronic transfer case shifting mechanism 1, and the range of the mechanical angle of each encoder is consistent with the range of the mechanical angle of each gear of the electronic transfer case shifting mechanism 1, and each encoder has a corresponding encoding value, the encoder 11 can feed back the gear signal of the electronic transfer case shifting mechanism 1 by feeding back the encoding value of the corresponding encoder.

[0056] In this embodiment, each code of the encoder 11 is distributed within each mechanical angle range of the encoder 11. Each code does not overlap with the others and together they form the entire code disk, which covers the entire 360-degree mechanical angle range of the encoder 11. Therefore, the position on the code disk referred to in this invention refers to a certain position on a certain code in the code disk.

[0057] In this embodiment, the manufacturer provides the design of the encoder 11 installed on the electronically controlled transfer case shifting actuator 1 at the factory. Through the structural design of the encoder 11's code disk and the relevant information on the range of each encoding mechanical angle, the code disk encoding distribution design diagram of the encoder 11 can be obtained, such as... Figure 7 As shown, the calibrated mechanical angle represents the angle range occupied by each code on the code disk, and the numbers represent the code value of each code.

[0058] This embodiment provides a detection device for the shift actuator of an electronically controlled transfer case, such as... Figures 8-11 As shown, it includes a detection and positioning unit 2, a data acquisition unit 3, and a calibration fixture 4;

[0059] like Figure 8 As shown, the detection and positioning unit 2 includes a rotary transformer 21 and a substrate 22. In this invention, rotary transformers with various pole pairs can be selected. For example, in this embodiment, the rotary transformer 21 is a six-pole rotary transformer.

[0060] like Figure 9 As shown, the rotary transformer 21 includes a resolver stator 211, a resolver rotor 212, a resolver rotor shaft 213, a resolver stator fixing plate 214, a resolver rotor fixing plate 215, and a slewing bearing 216.

[0061] The substrate 22 includes a through hole 221, a bonding surface 222, and a positioning pin 223;

[0062] The rotary transformer 21 is mounted on the bottom surface of the base plate 22. The rotary stator 211 and the rotary stator fixing plate 214 are connected by a stop-type positioning bolt, and the rotary stator fixing plate 214 is fixed to the bottom surface of the base plate 22 by a pin positioning bolt. The rotary rotor 212 and the rotary rotor shaft 213 are connected by a key. A slewing bearing 216 is provided between the rotary rotor shaft 213 and the rotary rotor fixing plate 215 to support the rotary rotor shaft 213 and allow the rotary rotor shaft 213 to rotate freely. The rotary rotor fixing plate 215 and the rotary stator fixing plate 214 are connected by a stop-type positioning bolt.

[0063] The data acquisition unit 3 includes a shift mechanism signal output component 31 and a resolver signal output component 32; the shift mechanism signal output component 31 is used to acquire the encoded value information output by the encoder 11; the resolver signal output component 32 is used to acquire the rotational electrical angle information output by the resolver 21.

[0064] like Figure 9 , Figure 10 The mating surface 222 shown is located on the upper surface of the substrate 22 and is used to mat with the lower surface of the electronically controlled transfer case shifting actuator 1. The first end face of the resolver rotor shaft 213 passes through the through hole 221. A triangular boss 217 is provided on the first end face of the resolver rotor shaft 213. The triangular boss 217 is used to match and connect with the first output hole 14 of the electronically controlled transfer case shifting actuator 1. The triangular boss 217 is in the shape of an isosceles triangle, which is not an equilateral triangle. A positioning pin 223 is provided on the mating surface 222. The positioning pin 223 is used to match and connect with the first shifting motor positioning hole 15 on the bottom plate of the electronically controlled transfer case shifting actuator 1.

[0065] By matching and connecting the triangular boss 217 with the first output hole 14 of the electronically controlled transfer case shifting actuator 1, the coaxial transmission between the resolver rotor shaft 213 and the output end of the gearbox 13 is realized. That is, the resolver rotor shaft 213 and the output end of the gearbox 13 rotate in the same direction of rotation and the same angular velocity. Finally, the resolver rotor shaft 213 and the encoder output shaft 111 rotate in the same direction of rotation and the same angular velocity.

[0066] like Figure 11 The calibration fixture 4 shown is provided with a triangular hole 41 that matches the triangular boss 217, and a mounting hole 42 that matches the positioning pin 223.

[0067] To achieve the goal of accurately measuring the mechanical angular position of each code in the encoder 11, and simultaneously detecting whether the installation angle of the encoder 11 on the electronically controlled transfer case shifting mechanism 1 meets the accuracy requirements and correcting the installation angle of the code generator 11 on the electronically controlled transfer case shifting mechanism 1 to meet the accuracy requirements, this embodiment also provides a detection method based on a detection device for the electronically controlled transfer case shifting mechanism provided in this embodiment.

[0068] Specifically, it includes the following steps:

[0069] Step 1: Calibrate the zero-point of the rotary transformer 21 using calibration fixture 4;

[0070] Step 2: Based on the encoded value information and rotational electrical angle information collected by the data acquisition unit 3, the electrical angle position in the rotary transformer 21 is mapped to each code on the code disk of the encoder 11, and the electrical angle position of the detection zero point in the rotary transformer 21 is obtained.

[0071] Step 3: Accurate detection and correction of the mounting angle of encoder 11 on the shift actuator 1 of the electronically controlled transfer case; then, through the code disk encoding distribution design of encoder 11, obtain the design mechanical angle distribution information of each code in encoder 11;

[0072] Step 4: Using the detection device, starting from the detection zero position, perform detection to obtain the detection mechanical angle distribution information of each code in the encoder 11;

[0073] Step 5: Compare the designed mechanical angle distribution information with the detected mechanical angle distribution information; determine whether the mechanical angle range of each code meets the design requirements based on the comparison results.

[0074] The specific implementation method of step 1 above is as follows: install the calibration fixture 4 on the detection and positioning unit 2, connect the triangular hole 41 on the calibration fixture 4 to the triangular boss 217, connect the mounting hole 42 on the calibration fixture 4 to the positioning pin 223, and take the electrical angle position of the rotary transformer 21 at this time as the detection zero position of the rotary transformer 21.

[0075] The specific implementation method of step 2 above is as follows: The rotary transformer 21 used in this embodiment is a six-pole rotary transformer. Taking any electrical zero position of the rotary transformer 21 as the starting point, the rotary sectors of the rotary transformer 21 are numbered sequentially as 0, 1, 2, 3, 4, and 5 according to the forward rotation direction of the rotary transformer 21.

[0076] At this time, the detection zero point of the resolver 21 can be represented as any resolver sector number and a rotational electrical angle output by the resolver 21 acquired by the resolver signal output component 32. In this embodiment, the detection zero point of the resolver 21 is set to resolver sector number 1, and the rotational electrical angle acquired by the resolver signal output component 32 is 48°, that is, the detection zero point of the resolver 21 is located at the position of 48° rotational electrical angle in resolver sector number 1.

[0077] The specific implementation method of step 3 above is as follows: remove the calibration fixture 4, install the electric transfer case shifting actuator 1 on the detection and positioning unit 2, connect the triangular boss 217 to the first output hole 14, and connect the positioning pin 223 to the first shifting motor positioning hole 15.

[0078] During this installation process, the resolver rotor shaft 213 may rotate. Before installation, the electronically controlled transfer case shifting actuator 1 can be driven to rotate in advance so that when the positioning pin 223 corresponds to the positioning hole 15 of the first shifting motor, the pointing direction of the first output hole 14 is consistent with the pointing direction of the triangular boss 217 before installation, so as to minimize the rotation amplitude of the resolver rotor shaft 213 during the installation process.

[0079] Then drive the electronically controlled transfer case shifting actuator 1 to rotate, so that the rotational electrical angle collected by the resolver signal output component 32 returns to the nearest 48° position, and the resolver 21 returns to the detection zero position.

[0080] Using any electrical zero position of the rotary transformer 21 as the mechanical zero position of the encoder 11, the electrical angle position in the rotary transformer 21 is converted into the mechanical angle position in the encoder 11. In this embodiment, the sector number n of the rotary transformer is taken as 0, and the rotation electrical angle Θ of the rotary transformer 21 is... 电 The electrical zero position of 0° is used as the mechanical zero position of encoder 11, and the correspondence between the electrical angle position in rotary transformer 21 and the mechanical angle position in encoder 11 is formed by formula 1, as shown in Table 1.

[0081] Θ 机 =n*(360° / N) 极对数 )+Θ 电 (Formula 1)

[0082] Where N 极对数 This indicates the number of pole pairs of the rotary transformer 21;

[0083] Where n represents the number of the refractive sector corresponding to the measured change in the code;

[0084] Where Θ 电 This indicates the electrical angle of rotation of the rotary transformer 21 corresponding to the location of the measured change in the code;

[0085] Where Θ 机 This indicates the mechanical angle in encoder 11 corresponding to the location of the measured change in the code;

[0086] Table 1: Correspondence between electrical angle positions in rotary transformers and mechanical angle positions in encoders

[0087]

[0088] Table 1 above shows that any mechanical angle in encoder 11 corresponds to a resolver sector number and a rotational electrical angle. This makes it possible to determine the corresponding mechanical angle in encoder 11 by obtaining the resolver sector number and the corresponding rotational electrical angle during subsequent detection. Formula 1 shows that the mechanical angle in encoder 11 corresponding to the detection zero position is 108°.

[0089] When the detection zero position corresponds to the first actual position on the encoder 11 code disk and aligns with the first designed position on the encoder 11 code disk, the installation angle accuracy requirement of the encoder 11 on the electronically controlled transfer case shifting actuator 1 is met. In this embodiment, the first designed position is located at the center of the code corresponding to the encoded value 9 (e.g., ...). Figure 12 (As shown).

[0090] The first actual position is determined by taking the position on the code disk corresponding to the zero detection position. Then, by correcting the installation angle of the encoder 11 on the shift actuator 1 of the electronically controlled transfer case, the first actual position is adjusted to align with the first designed position on the code disk. The specific method is as follows:

[0091] The signal output component 31 of the shift mechanism collects the encoding value corresponding to the return to the detection zero position. If the encoding value is 9, that is, the H gear range, the subsequent actions continue; if the encoding value is not 9, it means that the assembly angle of the encoder 11 is deviated, and the assembly angle of the encoder 11 on the shift actuator 1 of the electronically controlled transfer case needs to be corrected before the operation of this section is re-executed.

[0092] If the encoded value is 9, the electronically controlled transfer case shifting mechanism 1 is controlled to rotate clockwise from the detection zero position. When the encoder 11 is detected to have a value change of 8, the positive offset electrical angle of the rotary transformer 21 relative to the detection zero position is recorded. The electronically controlled transfer case shifting mechanism 1 is controlled to rotate counterclockwise from the detection zero position. When the encoder 11 is detected to have a value change of 1, the reverse offset electrical angle of the rotary transformer 21 relative to the detection zero position is recorded. Then, the electronically controlled transfer case shifting mechanism 1 is controlled to rotate again, so that the rotary transformer 21 returns to the detection zero position.

[0093] The offset electrical angle can be measured in various ways (for example, but not limited to, obtaining the positive and negative offset electrical angles based on the rotational electrical angle information fed back by the rotary transformer 21, and then combining the number of times the rotary transformer 21 passes through its electrical zero position during the clockwise and counterclockwise rotation processes to obtain the corresponding positive offset mechanical angle Θ). 正向偏移 and reverse offset mechanical angle Θ 反向偏 In this embodiment, since the rotary transformer 21 does not pass its electrical zero position during the clockwise and counterclockwise rotation processes, the corresponding positive offset mechanical angle Θ 正向偏移 and reverse offset mechanical angle Θ 反向偏移 The positive and negative offset electrical angles can be directly obtained from the above.

[0094] With Θ 实际扇区9 =Θ 正向偏移 +Θ 反向偏移 If |Θ 正向偏移-Θ 反向偏移 | / Θ 实际扇区9 If |Θ| <= 10%, it means that the first actual position has been adjusted to be within the allowable error range of the first designed position on the code disk, and that the accuracy of the encoder 11 assembly angle meets the requirements; if |Θ| <= 10%, it means that the first actual position has been adjusted to be within the allowable error range of the first designed position on the code disk, and that the accuracy of the encoder 11 assembly angle meets the requirements; 正向偏移 -Θ 反向偏移 | / Θ 实际扇区9 >10% indicates that the assembly angle of encoder 11 on the shift actuator 1 of the electronically controlled transfer case needs to be corrected before the operation of this section is re-executed.

[0095] In this embodiment, the first design position can be determined in various ways. For example, when the electronically controlled transfer case shift actuator 1 is manufactured, the manufacturer will point the apex of the first output hole 14 of the electronically controlled transfer case shift actuator 1 to a fixed direction, i.e., the factory position. At the same time, a preset position on the encoder disk corresponding to the first output hole 14 when it is in the factory position will be provided. Since the first output hole 14 has a pointing function, the angle of rotation of the apex of the first output hole 14 when it points to any direction relative to the apex of the first output hole 14 when it is in the factory position can be measured. Since the preset position on the encoder disk corresponding to the first output hole 14 when it is in the factory position is known, it can be determined by the encoder. The code disk encoding distribution design of encoder 11 is used to obtain the first design position on the code disk of encoder 11 at this time. After determining the apex direction of the first output hole 14 and obtaining the corresponding first design position, calibration fixture 4 is made. The triangular hole 41 corresponds to the shape, position and direction of the first output hole 14 at this time, and the mounting hole 42 corresponds to the shape and position of the first shift motor positioning hole 15 at this time. This can achieve the above step 3, when the mechanical angle position of the detection zero position in encoder 11 corresponding to the mapping relationship matches the first design position on the code disk of encoder 11, the installation angle accuracy requirement of encoder 11 on the shift actuator 1 of the electronically controlled transfer case is met.

[0096] At this point, the first designed position on the code disk is aligned with the detection zero position through the aforementioned mapping relationship (e.g., Figure 13 As shown in Table 2, the numbering table of the resolver sector corresponding to the intersection of each code in the encoder 11 is obtained through the code disk encoding distribution design of the encoder 11. At the same time, the design mechanical angle distribution information table of each code in the encoder 11 is obtained, as shown in Table 3.

[0097] Table 2. Numbering of the resolver sector corresponding to the intersection of each code in the design.

[0098]

[0099]

[0100] Table 3. Information on the distribution of design mechanical angles for each code in the encoder.

[0101]

[0102] The specific implementation method of step 4 above is as follows: taking the detection zero position as the starting point, drive the electronically controlled transfer case shifting actuator 1 to rotate counterclockwise. The data acquisition unit 3 acquires the encoded value output by the encoder 11 and the rotational electrical angle output by the rotary transformer 21. The program records the rotational electrical angle output by the rotary transformer 21 when the encoded value output by the encoder 11 changes. When the encoder 11 is detected to change to θ, the program records the rotary transformer electrical angle Θ at this time. 8电起始 The encoder 11 is located at the boundary between encoded value 9 and encoded value 8.

[0103] Next, obtain the resolver sector number corresponding to the boundary between code value 9 and code value 8. Then, the mechanical angle in the encoder corresponding to the boundary between code value 9 and code value 8 can be calculated using the formula 1 above. The resolver sector number corresponding to the boundary between code value 9 and code value 8 can be obtained in various ways (for example, but not limited to, by combining the number of times the resolver 21 passes through its electrical zero position during the counterclockwise rotation process, the resolver sector number corresponding to the boundary between code value 9 and code value 8 can be obtained).

[0104] In this embodiment, the resolver sector number n is obtained by combining the resolver sector numbering table (Table 2) corresponding to the intersection of each code in the design. 8起始 When the encoder 11 detects a change in its encoded value to 0, the program records that the resolver electrical angle Θ8 has terminated and that encoder 11 is at the boundary between encoded value 8 and encoded value 0. Combining this with the resolver sector numbering table (Table 2) corresponding to the boundaries of each encoded value in the design, the resolver sector number n at this time is obtained. 8终止 The starting and ending precise mechanical angles Θ8 of encoder 11, with a code value of 8, are calculated using formula 1 as follows:

[0105] Θ 8机起始 =n 8起始 *(360° / N 极对数 )+Θ 8电起始

[0106] Θ 8机终止 =n 8终止 *(360° / N 极对数 )+Θ 8机终止

[0107] Repeat the above steps, and use the control program to power on the shift motor and rotate it counterclockwise, and sequentially detect the precise mechanical angles of the start and end positions of other codes with values ​​of 0, 2, and 10.

[0108] Repeat the above steps, using the control program to power on the shift motor and rotate it clockwise, sequentially detecting the precise mechanical angles of the starting and ending positions of the codes with values ​​of 1, 3, 7, and 5. The precise mechanical angle of the code with a value of 9 has actually been measured in step 3 above, or can be derived from the precise mechanical angles of the codes with values ​​of 8 and 1.

[0109] Finally, the distribution information of the detection mechanical angles of each code in encoder 11 is obtained;

[0110] The specific implementation method of step 5 above is as follows: Based on the detection mechanical angle distribution information of each code in the encoder 11, compile a code-angle correspondence table for the gear shift actuator (e.g., Figure 14 As shown, the design of the shift actuator is compared with the design mechanical angle distribution information table compiled by the encoder 11. If the error of the code-angle interval distribution accuracy is not greater than 10%, it means that the product quality of the electronically controlled transfer case shift actuator 1 meets the requirements; if the error of the code-angle interval distribution accuracy exceeds 10%, it means that the product quality of the electronically controlled transfer case shift actuator 1 does not meet the requirements, and it needs to be reassembled and corrected, and then returned to step 1 above.

[0111] The detection device and method for the electronically controlled transfer case shifting actuator 1 provided in this embodiment achieve precise detection of the angle, position, and angle range between each of the codes, thereby accurately determining the installation quality of each of the codes of the encoder 11. At the same time, the calibration fixture 4 also achieves the precision detection and correction of the installation angle of the encoder 11 on the electronically controlled transfer case shifting actuator 1, thus comprehensively realizing the inspection of the product quality of the electronically controlled transfer case shifting actuator 1. The detection accuracy is high, and the structure is simple and easy to promote and popularize.

[0112] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A detection device for the shift actuator of an electronically controlled transfer case, characterized in that: Includes a detection and positioning unit and a data acquisition unit; The detection and positioning unit includes a rotary transformer and a base plate. The rotary transformer is integrally mounted on the bottom surface of the base plate. The rotary transformer includes a resolver rotor shaft. The base plate includes a through hole, a mating surface, and a positioning pin. The mating surface is located on the upper surface of the base plate and is used to mat with the lower surface of the electronically controlled transfer case shifting actuator with an encoder. The first end face of the resolver rotor shaft passes through the through hole. A triangular boss is provided on the first end face. The triangular boss is used to match and connect with the first output hole of the electronically controlled transfer case shifting actuator. The triangular boss is in the shape of an isosceles triangle, which is not an equilateral triangle. The positioning pin is provided on the mating surface and is used to match and connect with any shift motor positioning hole on the base plate of the electronically controlled transfer case shifting actuator. The data acquisition unit is used to acquire the encoded value information output by the encoder and the rotation electrical angle information output by the rotary transformer; The detection device for the shift actuator of the electronically controlled transfer case also includes a calibration fixture, which has a triangular hole that matches the triangular boss and a mounting hole that matches the positioning pin. The calibration fixture is used to calibrate the detection zero position of the rotary transformer, so that the electronically controlled transfer case shifting actuator is installed on the detection positioning unit, the triangular boss is connected to the first output hole, the positioning pin is connected to the first shifting motor positioning hole on the base plate of the electronically controlled transfer case shifting actuator, and then the electronically controlled transfer case shifting actuator is driven to rotate so that the rotary transformer returns to the detection zero position. The code corresponding to the detection zero position at this time and its position in the code should be consistent with the first design position on the encoder code disk.

2. A method for testing the shift actuator of an electronically controlled transfer case, characterized in that: The detection device for the electronically controlled transfer case shifting actuator as described in claim 1 is used, and the method includes the following steps: Step 1: Zero-point calibration of the rotary transformer; Step 2: Based on the encoded value information and rotational electrical angle information collected by the data acquisition unit, a mapping relationship is formed between the electrical angle position in the rotary transformer and each code on the encoder's code disk, and the electrical angle position of the detection zero point in the rotary transformer is obtained. Step 3: The detection device is used to detect the position of the detection zero point on the encoder's code disk corresponding to the mapping relationship. Then, the design mechanical angle distribution information of each code in the encoder is obtained through the code disk encoding distribution design of the encoder. Step 4: Using the detection device, starting from the detection zero position, perform detection to obtain the detection mechanical angle distribution information of each of the codes in the encoder; Step 5: Compare the designed mechanical angle distribution information with the detected mechanical angle distribution information; determine whether the mechanical angle range of each code meets the design requirements based on the comparison results.

3. The detection method for the shift actuator of the electronically controlled transfer case as described in claim 2, characterized in that: The method for calibrating the zero position of the rotary transformer in step 1 includes: installing the shifting actuator of the electronically controlled transfer case on the detection and positioning unit, connecting the triangular boss to the first output hole, connecting the positioning pin to the positioning hole of any shifting motor, and taking the electrical angle position in the rotary transformer at this time as the zero position of the rotary transformer.

4. The detection method for the shift actuator of the electronically controlled transfer case as described in claim 2, characterized in that: The specific implementation method of step 2 includes: installing the electronically controlled transfer case shifting actuator on the detection and positioning unit, connecting the triangular boss to the first output hole, connecting the positioning pin to any shifting motor positioning hole, taking any electrical zero position of the rotary transformer as the starting point, sequentially numbering each resolver sector of the rotary transformer according to the forward rotation direction of the rotary transformer, and making the electrical angle position in the rotary transformer and each of the codes on the encoder disk form a mapping relationship according to the encoding value information and rotation electrical angle information collected by the data acquisition unit, setting the detection zero position in any numbered resolver sector, and obtaining the electrical angle position of the detection zero position in the rotary transformer according to the rotation electrical angle information collected by the data acquisition unit.

5. The detection method for the shift actuator of the electronically controlled transfer case as described in claim 2, characterized in that: The specific implementation method of step 3 includes: taking the position of the detection zero point detected by the detection device and corresponding to the code disk through the mapping relationship as the first actual position, finding the position of the first actual position in the code disk encoding distribution design, and then taking any electrical zero point of the rotary transformer as the mechanical zero point of the encoder to obtain the mechanical angle position of the first actual position in the encoder, and then obtaining the design mechanical angle distribution information of each code in the encoder through the code disk encoding distribution design.

6. The detection method for the shift actuator of the electronically controlled transfer case as described in claim 2, characterized in that: The method for calibrating the zero position of the rotary transformer in step 1 includes: installing the calibration fixture on the detection positioning unit, connecting the triangular hole on the calibration fixture to the triangular boss, connecting the mounting hole on the calibration fixture to the positioning pin, and taking the electrical angle position in the rotary transformer at this time as the zero position of the rotary transformer. The specific implementation of step 2 includes: taking any electrical zero point of the rotary transformer as the starting point, numbering each sector of the rotary transformer sequentially according to the forward rotation direction of the rotary transformer, setting the detection zero point in any numbered sector, and obtaining the electrical angle position of the detection zero point in the rotary transformer based on the rotational electrical angle information collected by the data acquisition unit; then removing the calibration fixture, installing the electronically controlled transfer case shifting actuator on the detection positioning unit, connecting the triangular boss to the first output hole, and connecting the positioning pin to the first shifting motor positioning hole, wherein the first shifting motor positioning hole is a specific shifting motor positioning hole; and, based on the encoded value information and rotational electrical angle information collected by the data acquisition unit, making the electrical angle position in the rotary transformer and each of the codes on the encoder's code disk form a mapping relationship. The specific implementation of step 3 includes: driving the electronically controlled transfer case shifting actuator to rotate so that the rotary transformer returns to the detection zero position; detecting the detection zero position through the detection device to obtain the position on the code disk corresponding to the mapping relationship as the first actual position; then adjusting the installation angle of the encoder on the electronically controlled transfer case shifting actuator to adjust the first actual position to the first designed position on the code disk so that the installation angle of the encoder on the electronically controlled transfer case shifting actuator meets the design requirements; finding the position corresponding to the first actual position in the code disk encoding distribution design; then obtaining the mechanical angle position of the first actual position in the encoder by taking any electrical zero position of the rotary transformer as the mechanical zero position of the encoder; and finally obtaining the designed mechanical angle distribution information of each code in the encoder through the code disk encoding distribution design.

7. The detection method for the shift actuator of the electronically controlled transfer case as described in claim 6, characterized in that: In step 3, the first design position is located in the non-blocking area of ​​the code disk, and the first design position is the middle position of any of the codes or the boundary of adjacent codes.

8. The method for detecting the shift actuator of the electronically controlled transfer case as described in any one of claims 5 and 6, characterized in that: In step 3, the specific implementation method of obtaining the position of the detection zero point on the code disk corresponding to the mapping relationship through the detection device as the first actual position includes: acquiring the encoding value output by the encoder at the detection zero point through the data acquisition unit to obtain the encoding corresponding to the detection zero point through the mapping relationship; then, taking the detection zero point as the starting point, the electronically controlled transfer case shifting actuator rotates forward and reverse to the first change point of the encoding value of the encoding, respectively, and measuring the positive offset electrical angle and the reverse offset electrical angle relative to the detection zero point, thereby obtaining the encoding corresponding to the first actual position and the positive offset mechanical angle and the reverse offset mechanical angle of the two ends of the encoding relative to the first actual position, that is, obtaining the current position of the first actual position on the code disk.

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