A high-power electric drive gearbox passive heat dissipation test bench and test method

Abstract

The present invention discloses a high-power electric drive gearbox passive heat dissipation test bench and test method. A high-power fan and an air rectifier and temperature-regulating pipe are used to realize that the airflow on the surface of the gearbox to be tested is parallel and the temperature is controllable. The lifting mechanism enables the test bench to adapt to the test requirements of gearboxes to be tested with different center distances, thereby improving the versatility of the test bench. At the same time, due to the transmission characteristics of the lead screw, the lifting mechanism makes the position of the gearbox self-locking, thereby improving the safety during use. The four guide rails of the lifting mechanism also play a role in improving the transmission accuracy. The application of the universal coupling reduces the requirements for assembly accuracy during the bench test process. The simultaneous use of the drive motor and the load motor enables the test bench to simulate all working conditions when the whole machine is used. The transmission device of the drive motor is located on the back of the gearbox to be tested, and does not interfere with the gas flow on the front of the gearbox, thereby improving the consistency of the gas flow during different working condition tests.

Description

Technical Field

[0001] The present invention relates to the field of electric drive variable speed transmission, and in particular to a high-power electric drive gearbox passive heat dissipation test bench and a test method. Background Art

[0002] In the past decade, whether it is passenger cars, commercial vehicles or construction machinery, the electric drive has ushered in a wave. The electrification of vehicles can greatly reduce the consumption of oil resources in related industries, which provides a major breakthrough in energy conservation and emission reduction, reduces vehicle exhaust emissions, protects the atmospheric environment, and reduces the probability of natural environmental disasters such as photochemical smog, haze weather, and acid rain.

[0003] However, due to the continuous improvement of motor performance, the current electric drive transmission has eliminated the hydraulic transmission device and the supporting active heat dissipation mechanism compared to the traditional internal combustion engine transmission. This makes the heat generated by the power loss conversion in the power transmission process mainly dissipated through the convection heat exchange between the box surface and the air. However, due to the complexity of gas flow, it is difficult to complete the thermal balance test of the electric drive transmission in a laboratory environment because there is no special thermal balance test bench for the electric drive transmission. In order to complete the thermal balance test of the electric drive transmission in a laboratory environment, we provide a high-power electric drive transmission passive heat dissipation test bench and test method. Summary of the invention

[0004] The purpose of the present invention is to solve the above-mentioned problem and to provide a high-power electric drive gearbox passive heat dissipation test bench and test method.

[0005] A high-power electric drive gearbox passive heat dissipation test bench comprises a base, a base frame is mounted on the base, a drive motor is mounted on the base frame, the drive motor is connected to an input end of an input end torque speed sensor through a first coupling, bearings are mounted on both sides of the input end torque speed sensor, an output end of the input end torque speed sensor is connected to an input shaft of a gearbox to be tested through a second coupling, a load motor is mounted on the base, the load motor is connected to an output end of a bevel gearbox through a second universal coupling, and the input end of the bevel gearbox is connected to an output end of the torque speed sensor through a third coupling. The output end is connected, the input end of the output end torque speed sensor is connected to the output shaft of the gearbox to be tested through the first universal joint, the base is sunken with a lift, the gearbox to be tested is installed on the lift, the gearbox to be tested is provided with an oil temperature sensor, the base is installed with a large fan in the direction of the gearbox to be tested, the front of the large fan is installed with an air rectifier temperature regulating box, the side of the gearbox to be tested is installed with a thermal imager, the base is also installed with a power distribution cabinet, the power distribution cabinet controls the operation of the entire device, and the base frame can also be detachably installed with a top shield and a side shield for protection;

[0006] The power distribution cabinet is provided with a frequency converter, a multi-channel data acquisition system, a gear controller, an instrument panel and a complete machine switch;

[0007] The air rectifying and thermostatic box comprises a box shell and a pipeline, the pipeline is arranged in the box shell, the box shell is seamlessly connected with the large fan, the axis of the pipeline is parallel to the axis of the input shaft of the gearbox to be tested, and a pipeline temperature sensor is arranged on the air rectifying and thermostatic box;

[0008] The pipeline is a narrow and elongated hollow cylindrical pipeline, the pipeline is stacked inside the box shell, and the gap between the pipelines can be filled with heat exchange medium to adjust the pipeline temperature;

[0009] The elevator includes a high-torque motor, a synchronous toothed belt, a motor fixing bracket, a gearbox mounting seat, a pulley, a threaded screw and a guide rail. The high-torque motor is fixed by the motor fixing bracket and is connected to the pulley through a synchronous toothed belt. The rotation of the pulley drives the threaded screw to move axially. A gearbox mounting seat is fixed above the screw. The guide rail is located around the gearbox mounting seat and is parallel to the threaded screw. The guide rail plays a guiding role during the rising and falling process of the gearbox mounting seat.

[0010] A high-power electric drive gearbox passive heat dissipation test method comprises the following steps:

[0011] S1, install the gearbox to be tested on the elevator, adjust the elevator to adjust the gearbox to be tested to a suitable height, connect the input shaft of the gearbox to be tested to the output end of the input end torque speed sensor through the second coupling, and connect the output shaft of the gearbox to be tested to the input end of the output end torque speed sensor through the first universal coupling;

[0012] S2, turning on the oil temperature sensor to monitor the oil temperature of the oil inside the gearbox to be tested;

[0013] S3, turn on the large fan and adjust the temperature of the pipes in the air rectifier thermostat to ensure that the high-speed airflow temperature on the surface of the gearbox to be tested is consistent with that when the vehicle is working;

[0014] S4, when the internal oil temperature of the gearbox to be tested is room temperature, the drive motor and the load motor are turned on according to the test conditions, and the torque, speed and oil temperature of the input shaft and output shaft of the gearbox to be tested are recorded;

[0015] S5: If the oil temperature measured by the oil temperature sensor is greater than 120°C during the test, the drive motor and the load motor should be turned off immediately, and the test should be repeated when the oil temperature drops to room temperature.

[0016] S6: When the temperature rise rate of the oil inside the gearbox under test is lower than 0.1℃ / min, the thermal equilibrium state is reached by default. The surface temperature of the box is recorded using a thermal imager, and the drive motor and load motor are turned off.

[0017] S7, repeating steps S4-S6 for the new test condition;

[0018] S8, compares the average temperature rise rate of the process of reaching thermal equilibrium under different working conditions to analyze the passive heat dissipation state of the gearbox.

[0019] Beneficial effects of the present invention:

[0020] The invention provides a passive heat dissipation test bench for a high-power electric drive gearbox and an experimental method thereof, which adopts a high-power fan and an air rectifier temperature-regulating pipe to realize that the airflow on the surface of the gearbox to be tested is parallel and the temperature is controllable. The lifting mechanism enables the test bench to adapt to the test requirements of the gearbox to be tested with different center distances, thereby improving the versatility of the test bench. At the same time, due to the transmission characteristics of the lead screw, the position of the gearbox is self-locking, which improves the safety during use. The four guide rails of the lifting mechanism also play a role in improving the transmission accuracy. The application of the universal coupling reduces the requirements for assembly accuracy during the bench test process. The simultaneous use of the drive motor and the load motor enables the test bench to simulate all working conditions when the whole machine is used. The transmission device of the drive motor is located on the back of the gearbox to be tested, and does not interfere with the gas flow on the front of the gearbox, thereby improving the consistency of the gas flow during different working conditions. The rational use of the thermal imager realizes the rapid evaluation of the temperature distribution on the surface of the box, which is convenient for the optimization of the structure of the box surface to continuously improve the heat dissipation performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a three-dimensional schematic diagram of the present invention;

[0022] Figure 2 It is a schematic diagram of the transmission mechanism inside the shield of the present invention;

[0023] Figure 3 It is a schematic diagram of the transmission mechanism inside the elevator of the present invention;

[0024] Figure 4 It is a schematic diagram of the interior of the air rectification and temperature regulating box of the present invention;

[0025] Figure 5 It is a schematic diagram of the internal structure of the control cabinet of the present invention;

[0026] Figure 6 It is a flowchart of the test steps of the present invention.

[0027] The numbers in the figure are:

[0028] 1. Power distribution cabinet, 2. Top guard, 3. Gearbox to be tested, 4. Thermal imager, 5. Pipeline temperature sensor, 6. Air rectifier thermostat, 7. Large fan, 8. Lift, 9. Oil temperature sensor, 10. Side guard, 11. Load motor, 12. Drive motor, 13. First coupling, 14. Bearing, 15. Input torque speed sensor, 16. First universal coupling, 17. Output torque speed sensor, 18. Bevel gear Box, 19. Second universal joint, 20. High torque motor, 21. Synchronous toothed belt, 22. Motor fixing bracket, 23. Gearbox mounting seat, 24. Pulley, 25. Threaded screw, 26. Guide rail, 27. Box shell, 28. Pipeline, 29. Frequency converter, 30. Multi-channel data acquisition system, 31. Gear controller, 32. Instrument panel, 33. Machine switch, 34. Base, 35. Base frame, 36. Second coupling, 37. Third coupling. DETAILED DESCRIPTION

[0029] See also Figures 1 to 6 As shown, a high-power electric drive gearbox passive heat dissipation test bench includes a base 34, a base frame 35 is installed on the base 34, a drive motor 12 is installed on the base frame 35, the drive motor 12 is connected to the input end of the input end torque speed sensor 15 through a first coupling 13, bearings 14 are installed on both sides of the input end torque speed sensor 15, the output end of the input end torque speed sensor 15 is connected to the input shaft of the gearbox 3 to be tested through a second coupling 36, a load motor 11 is installed on the base 34, the load motor 11 is connected to the output end of the bevel gearbox 18 through a second universal coupling 19, and the input end of the bevel gearbox 18 is connected to the output end torque through a third coupling 37. The output end of the speed sensor 17 is connected, and the input end of the output end torque speed sensor 17 is connected to the output shaft of the gearbox 3 to be tested through the first universal coupling 16. A lifter 8 is installed on the base 34 in a sunken manner, and the gearbox 3 to be tested is installed on the lifter 8. An oil temperature sensor 9 is provided on the gearbox 3 to be tested. A large fan 7 is installed on the base 34 in the direction of the gearbox 3 to be tested, and an air rectifier and temperature regulating box 6 is installed in front of the large fan 7. A thermal imager 4 is installed on the side of the gearbox 3 to be tested. A power distribution cabinet 1 is also installed on the base 34, and the power distribution cabinet 1 controls the operation of the entire device. The base frame 35 can also be detachably installed with a top shield 2 and a side shield 10 for protection;

[0030] The power distribution cabinet 1 is provided with a frequency converter 29, a multi-channel data acquisition system 30, a gear controller 31, an instrument panel 32 and a whole machine switch 33;

[0031] The air rectifying and thermostatic box 6 includes a box shell 27 and a pipeline 28. The pipeline 28 is arranged in the box shell 27. The box shell 27 is seamlessly connected with the large fan 7. The axis of the pipeline 28 is parallel to the axis of the input shaft of the gearbox 3 to be tested. The air rectifying and thermostatic box 6 is provided with a pipeline temperature sensor 5.

[0032] Specifically, the drive motor 12 , the load motor 11 and the large fan 7 are controlled by the frequency converter 29 , and the input shaft torque speed sensor 15 , the output shaft torque speed sensor 17 , the oil temperature sensor 9 and the air rectifier thermostat temperature sensor 5 are connected together in a multi-channel data acquisition system 30 .

[0033] The pipeline 28 is a narrow and elongated hollow cylindrical pipeline, and the pipeline 28 is stacked inside the box shell 27. The gap between the pipelines 28 can be filled with heat exchange medium to adjust the pipeline temperature;

[0034] The elevator 8 includes a high-torque motor 20, a synchronous toothed belt 21, a motor fixing bracket 22, a gearbox mounting seat 23, a pulley 24, a threaded screw 25 and a guide rail 26. The high-torque motor 20 is fixed by the motor fixing bracket 22 and is connected to the pulley 24 through the synchronous toothed belt 21. The rotation of the pulley 24 drives the threaded screw 25 to move axially. A gearbox mounting seat 23 is fixed above the screw 25. The guide rail 26 is located around the gearbox mounting seat 23 and is parallel to the threaded screw 25. The guide rail 26 plays a guiding role in the rising and falling process of the gearbox mounting seat 23.

[0035] A high-power electric drive gearbox passive heat dissipation test method comprises the following steps:

[0036] S1, install the gearbox 3 to be tested on the elevator 8, adjust the elevator 8 to adjust the gearbox 3 to be tested to a suitable height, connect the input shaft of the gearbox 3 to be tested to the output end of the input end torque speed sensor 15 through the second coupling 36, and connect the output shaft of the gearbox 3 to be tested to the input end of the output end torque speed sensor 17 through the first universal coupling 16;

[0037] S2, turning on the oil temperature sensor 9 to monitor the oil temperature of the oil inside the gearbox 3 to be tested;

[0038] S3, turning on the large fan 7, adjusting the temperature of the pipe 28 in the air rectifier thermostat 6, and ensuring that the high-speed airflow temperature on the surface of the gearbox 3 to be tested is consistent with that when the vehicle is working;

[0039] S4, when the internal oil temperature of the gearbox 3 to be tested is at room temperature, the drive motor 12 and the load motor 11 are turned on according to the test conditions, and the torque, speed and oil temperature of the input shaft and output shaft of the gearbox to be tested are recorded;

[0040] S5, during the test, if the oil temperature measured by the oil temperature sensor 9 is greater than 120°C, the drive motor 12 and the load motor 11 should be turned off immediately, and the test should be repeated when the oil temperature drops to room temperature;

[0041] S6, when the temperature rise rate of the oil inside the gearbox 3 to be tested is lower than 0.1°C / min, the thermal equilibrium state is reached by default, the surface temperature of the box is recorded using the thermal imager 4, and the drive motor 12 and the load motor 11 are turned off;

[0042] S7, repeating steps S4-S6 for the new test condition;

[0043] S8, compares the average temperature rise rate of the process of reaching thermal equilibrium under different working conditions to analyze the passive heat dissipation state of the gearbox.

Claims

1. A high-power electric drive gearbox passive heat dissipation test bench, comprising a base (34), characterized in that: A base frame (35) is mounted on the base (34), a driving motor (12) is mounted on the base frame (35), the driving motor (12) is connected to an input end of an input torque speed sensor (15) via a first coupling (13), bearings (14) are mounted on both sides of the input torque speed sensor (15), the output end of the input torque speed sensor (15) is connected to an input shaft of a gearbox (3) to be tested via a second coupling (36), a load motor (11) is mounted on the base (34), the load motor (11) is connected to an output end of a bevel gearbox (18) via a second universal coupling (19), the input end of the bevel gearbox (18) is connected to an output end of the output torque speed sensor (17) via a third coupling (37), and the output end The input end of the torque speed sensor (17) is connected to the output shaft of the gearbox to be tested (3) through a first universal joint (16); a lifter (8) is installed in a sunken manner on the base (34); the gearbox to be tested (3) is installed on the lifter (8); an oil temperature sensor (9) is provided on the gearbox to be tested (3); a large fan (7) is installed on the base (34) in the direction of the gearbox to be tested (3); an air rectifier temperature control box (6) is installed in front of the large fan (7); a thermal imager (4) is installed on the side of the gearbox to be tested (3); a power distribution cabinet (1) is also installed on the base (34); the power distribution cabinet (1) controls the operation of the entire device; and the base frame (35) is also detachably installed with a top shield (2) and a side shield (10) for protection.

2. A high-power electric drive gearbox passive heat dissipation test bench according to claim 1, characterized in that: The power distribution cabinet (1) is internally provided with a frequency converter (29), a multi-channel data acquisition system (30), a gear controller (31), an instrument panel (32) and a complete machine switch (33).

3. A high-power electric drive gearbox passive heat dissipation test bench according to claim 2, characterized in that: The air rectifying and thermostatic box (6) comprises a box shell (27) and a pipeline (28), wherein the pipeline (28) is arranged in the box shell (27), the box shell (27) and the large fan (7) are seamlessly connected, the axis of the pipeline (28) is parallel to the axis of the input shaft of the gearbox (3) to be tested, and a pipeline temperature sensor (5) is arranged on the air rectifying and thermostatic box (6).

4. A high-power electric drive gearbox passive heat dissipation test bench according to claim 3, characterized in that: The pipeline (28) is a narrow and elongated hollow cylindrical pipeline. The pipeline (28) is stacked inside the box shell (27), and the gaps between the pipelines (28) can be filled with heat exchange medium to adjust the pipeline temperature.

5. A high-power electric drive gearbox passive heat dissipation test bench according to claim 4, characterized in that: The elevator (8) comprises a high-torque motor (20), a synchronous toothed belt (21), a motor fixing bracket (22), a gearbox mounting seat (23), a pulley (24), a threaded screw (25) and a guide rail (26). The high-torque motor (20) is fixed by the motor fixing bracket (22) and connected to the pulley (24) via the synchronous toothed belt (21). The pulley (24) rotates to drive the threaded screw (25) to move axially. A gearbox mounting seat (23) is fixed above the screw (25). The guide rail (26) is located around the gearbox mounting seat (23) and is parallel to the threaded screw (25). The guide rail (26) plays a guiding role in the process of the gearbox mounting seat (23) rising and falling.

6. A high-power electric drive gearbox passive heat dissipation test method based on a high-power electric drive gearbox passive heat dissipation test bench according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1, installing the gearbox (3) to be tested on the lift (8), adjusting the lift (8) to adjust the gearbox (3) to be tested to a suitable height, connecting the input shaft of the gearbox (3) to be tested with the output end of the input end torque speed sensor (15) through the second coupling (36), and connecting the output shaft of the gearbox (3) to be tested with the input end of the output end torque speed sensor (17) through the first universal coupling (16); S2, turning on the oil temperature sensor (9) to monitor the oil temperature of the oil inside the gearbox (3) to be tested; S3, turning on the large fan (7) and adjusting the temperature of the pipe (28) in the air rectifier thermostat (6) to ensure that the high-speed airflow temperature on the surface of the gearbox (3) to be tested is consistent with that when the whole vehicle is in operation; S4, when the internal oil temperature of the gearbox to be tested (3) is at room temperature, the drive motor (12) and the load motor (11) are turned on according to the test conditions, and the torque, speed and oil temperature of the input shaft and the output shaft of the gearbox to be tested are recorded; S5: During the test, if the oil temperature measured by the oil temperature sensor (9) is greater than 120°C, the drive motor (12) and the load motor (11) should be turned off immediately, and the test should be repeated when the oil temperature drops to room temperature; S6, when the temperature rise rate of the oil inside the gearbox (3) to be tested is lower than 0.1°C / min, a thermal equilibrium state is reached by default, a thermal imager (4) is used to record the surface temperature of the gearbox, and the drive motor (12) and the load motor (11) are turned off; S7, repeating steps S4-S6 for the new test condition; S8, compares the average temperature rise rate of the process of reaching thermal equilibrium under different working conditions to analyze the passive heat dissipation state of the gearbox.

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