Parallel adjustable universal load simulator

Abstract

The application discloses a parallel adjustable general load simulator for realizing load simulation test of different products, and meets various servo product index requirements and product batch production demands; the load simulator is highly integrated, greatly saves the floor area of a production workshop, and is provided with a limiting protection design in structure optimization, can comprehensively simulate hinge torque, inertia, rigidity and friction load, and is continuously adjustable to a certain extent, so that servo test data can more directly reflect dynamic and static characteristics of the product.

Description

Technical Field

[0001] This invention relates to a parallel adjustable universal load simulator, belonging to the field of servo mechanism technology. Background Technology

[0002] As a subsystem of the launch vehicle control system, the servo mechanism receives control commands from the flight control system, follows control signals, and dynamically adjusts its flight attitude during flight to achieve pitch, yaw, and roll control. With the rapid development of aerospace technology, higher demands are being placed on the testing of aerospace servo products: high-precision testing of servo products is required, as well as meeting the requirements of simulating real loads. Currently, the testing load equipment for servo products used in projects generally adopts a "each project has its own load equipment" approach, resulting in large sizes, low efficiency, and high costs, which is detrimental to the later mass production of the product. Summary of the Invention

[0003] The technical problem to be solved by this invention is to overcome the shortcomings of the prior art and solve the problems of inconvenient installation and operation of servo products on the actual control cabin of aircraft, limited space, and decreased load accuracy and stability caused by various factors such as wear of mechanical parts after long-term use.

[0004] The objective of this invention is achieved through the following technical solutions:

[0005] A parallel adjustable universal load simulator includes column I, column II, protective cover, platform, and two primary submechanisms;

[0006] After the protective cover and the platform are connected, a cavity with an opening on one side is formed. Column II is located inside the cavity, and column I is located outside the cavity.

[0007] The two primary submechanisms are identical and are mounted back-to-back on columns I and II; that is, a part of each primary submechanism is located inside the cavity.

[0008] Each primary submechanism includes two secondary submechanisms and a stiffness adjustment mechanism; the two secondary submechanisms are arranged vertically and each is connected to one end of a servo product under test, and both servo products under test are connected to the stiffness adjustment mechanism; the stiffness adjustment mechanism simulates different installation stiffness by adjusting the effective extension length of its own lug, wherein the lug is connected to the servo product under test.

[0009] Each secondary submechanism includes a limit protection mechanism, a hinge torque adjustment mechanism, an inertia adjustment mechanism, a friction loading mechanism, a product encoder, a spring steel plate, a rocker arm, and a rotating shaft. The other end of the servo product under test is connected to the rotating shaft via the rocker arm. The limit protection mechanism is mounted on column I to limit one end of the rotating shaft. The friction loading mechanism is used to apply friction torque to the rotating shaft. The other end of the rotating shaft is limited by the hinge torque adjustment mechanism via the spring steel plate. The hinge torque adjustment mechanism simulates different hinge torques by adjusting the effective length of the spring steel plate. The inertia adjustment mechanism is mounted on the rotating shaft to simulate and adjust inertial loads. The product encoder is used to measure the swing angle of the load simulator.

[0010] Preferably, each secondary sub-mechanism also includes a control driver interface module for adapting to the servo product under test.

[0011] Preferably, the product encoder is concentric with the rotating shaft, and the swing angle is fed back by the product encoder when the rocker arm swings with the rotating shaft.

[0012] Preferably, each limit protection mechanism includes a mounting base, a pin, a limit member I, and a limit member II. The limit member II is fixedly connected to the mounting base, and the limit member I is fixedly connected to the rotating shaft. When the rotating shaft swings, the limit member I swings accordingly. The limit protection function is achieved by limiting the angle between the left and right ends of the limit member II and the limit member I.

[0013] Preferably, the friction loading mechanism is implemented by using a disc spring loading friction pair method with multiple sets of parallel overlapping and straight combination.

[0014] Preferably, the hinge torque adjustment mechanism includes an upper pressure plate, a lower pressure plate, an adjusting seat, a fixed seat, and a threaded plate; the positions of the upper pressure plate and the lower pressure plate on the adjusting seat are adjusted, the adjusting seat is installed on the fixed seat, and the fixed seat is installed and fixed on the column II.

[0015] Preferably, the friction loading mechanism includes an adjustable nut, a disc, a needle roller, a disc spring assembly, a spring shaft, a friction shaft, and a cage. The adjustable nut is mounted on the disc in a cross-symmetrical manner. The disc is fixed on the mounting base of the limit protection mechanism. The disc spring assembly is mounted on one side of the needle roller and the cage. The adjustable nut, needle roller, and disc spring assembly are all mounted on the spring shaft.

[0016] Preferably, the stiffness adjustment mechanism includes a mounting base, clamping member I, clamping member II, upper support lug, and connecting plate. Clamping member I and clamping member II are both fixed to the connecting plate, and clamping member I and clamping member II are connected to the mounting base. By adjusting the installation position of clamping member I and clamping member II on the upper support lug and the mounting base, the static stiffness and structural strength are improved.

[0017] Preferably, rectangular grooves are provided on both sides of the mounting base. In order to fix the clamping member I to the groove of the mounting base, the side of the clamping member I protrudes. In order to fix the clamping member II to the upper support ear, a protrusion is provided on one side of the clamping member II to match the upper support ear, so as to adjust the effective extension length of the upper support ear.

[0018] Preferably, when using the load simulator, one end of the servo mechanism under test is mounted on the stiffness adjustment mechanism via a pin, and the other end is mounted on the rocker arm via a rocker arm pin; when the servo mechanism moves, it drives the rocker arm and the rotating shaft to swing.

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] (1) This invention utilizes the stiffness adjustment mechanism of the upper and lower workstations of column I as one unit, and is symmetrically distributed on both sides. Through series and parallel design, coaxial layout and parallel loading method, this load invention can effectively utilize the upper space position, adopts a small and lightweight space structure form that integrates four workstations, and the load is small and highly integrated. The load simulator adopts an external layout, which is convenient for personnel to install and operate the product.

[0021] (2) The present invention uses a limiting member installed on the rotating shaft and a limiting member II fixed on the mounting base to work together to effectively limit the rocker arm and the rotating shaft. This design leaves a certain margin within the swing angle range required by the load simulation, limits its swing range, and controls it within the maximum swing angle range. In addition, the simulator limit protection is designed with a polyurethane rubber pad to protect the product.

[0022] (3) This invention achieves its effect by employing a multi-set parallel overlapping + straight combination of disc springs to load friction pairs. To increase the friction contact area and expand the adjustable friction torque range, the contact surface between the friction shaft and the rotating shaft is designed as a semi-circular shape. In the "friction loading mechanism," multiple sets of adjustable clamping disc springs press the friction plates onto the friction ring. Adjusting the clamping force of the disc springs adjusts the pressure applied to the friction plates, thereby adjusting the friction torque. This achieves continuous loading and adjustment of the friction torque within a specific range. This friction loading structure is simple, easy to operate, and has a low cost.

[0023] (4) In the first scheme of the column I of the present invention, different threaded hole interfaces are provided according to the model of the control driver. The adjustable control driver interface module can be adapted to different control drivers. According to the cable network length requirements, this module can move with the product interface size to adapt to different models of cable network design. In the second scheme, a guide rail is provided on the side of the column I, and a control driver mounting plate is provided above the guide rail. The positioning and movement on the guide rail is realized according to the model of the control driver adapted on the mounting plate. This design ensures the compatibility between models, that is, this parallel adjustable universal load simulator can be used for the installation of various models of servo.

[0024] (5) The parallel adjustable universal load simulator of the present invention adopts the product encoder method for measuring the swing angle. It has one-click zeroing and automatic calibration functions. The traditional method uses angular displacement sensor, which requires manual zeroing of angular displacement before acceptance testing. The zeroing process is cumbersome, and the sensor needs to be tapped during the zeroing process, which affects the life of the sensor.

[0025] (6) This invention utilizes the installation distance of the upper lugs of the stiffness adjustment mechanism and provides different models of lug interface modules to achieve the purpose of testing the working performance of the servo mechanism under different installation stiffnesses, thereby improving the versatility of this load simulator and making it applicable to the simulation of loading torque of various models of servo. It proposes to combine inertia plates to simulate and adjust the inertia value, thereby achieving high-reliability simulation of multiple models and multiple inertia, meeting the requirement of continuous adjustment within the required range, improving the versatility of this load device, and also improving the reliability of product testing. Attached Figure Description

[0026] Figure 1 Parallel adjustable general-purpose load simulator structural assembly diagram;

[0027] Figure 2 Schematic diagram of limit protection mechanism;

[0028] Figure 3 Schematic diagram of friction loading mechanism;

[0029] Figure 4 Schematic diagram of hinge torque adjustment mechanism;

[0030] Figure 5 Schematic diagram of the installation distance of the adjustment plate;

[0031] Figure 6 Schematic diagram of stiffness adjustment mechanism. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0033] A parallel adjustable universal load simulator is disclosed to realize load simulation testing of different products. The load simulator described in this invention can meet the performance requirements of various servo products and the needs of mass production. Moreover, the load simulator is highly integrated, which greatly saves the floor space of the production workshop. The load simulator has a limit protection design during structural optimization. It can comprehensively simulate hinge torque, inertia, stiffness and friction load. The load is continuously adjustable to a certain extent, so that the servo test data can more intuitively reflect the dynamic and static characteristics of the product.

[0034] A parallel adjustable universal load simulator is disclosed, which mainly consists of a stiffness adjustment mechanism 1, a hinge torque adjustment mechanism 2, an inertia adjustment mechanism 3, a friction loading mechanism 4, a control driver interface module 5, a product encoder 6, a column I 7, a protective cover 8, a platform 9, a spring steel plate 10, a rocker arm 11, a rotating shaft 12, a column II 13, and a limit protection mechanism 14. The inertia adjustment mechanisms, friction loading mechanisms, rotating shafts, and rocker arms on the same side of column I 7 are symmetrically distributed on the platform 9 relative to the stiffness adjustment mechanism. The load simulator is arranged in a cross-symmetric manner on column I 7. The hinge torque adjustment mechanisms 2 (four positions) are also symmetrically arranged in a cross-symmetric manner on column II 13. Columns I 7 and II 13 (both made of Q235A carbon structural steel, which has good plasticity and toughness, as well as good weldability and hot workability) are equipped with lifting rings on their tops for easy lifting. The control driver interface module 5 is located on the side of column I 7. The product encoder 6 is installed on one side of the friction loading mechanism. The product encoder is concentric with the rotating shaft 12. The rocker arm 11 swings with the rotating shaft 12, and the swing angle is fed back by the product encoder. The assembly drawing of the parallel adjustable universal load simulator structure is attached. Figure 1 .

[0035] The limit protection mechanism includes a mounting base 111, a pin 112, a limit member I 113, and a limit member II 114. The limit member II 114 is fixedly connected to the mounting base 111, and the limit member I 113 is fixedly connected to the rotating shaft 12. When the rotating shaft 12 swings, the limit member I 113 swings accordingly. The limit member I 113 is limited by the angle between the left and right ends of the limit member II 114 and the limit member I 113, thus playing a limit protection role.

[0036] The present invention will be further described in detail with reference to the accompanying drawings.

[0037] Limit protection design as attached Figure 2As shown, the limiting protection mechanism includes a mounting base 111, a pin 112, a limiting component I 113, and a limiting component II 114. Limiting component I 113 (made of 45# steel, possessing higher strength and resistance to deformation) is fixedly connected to the rotating shaft 12 by a set of first screws 1. Limiting component II 114 (made of Q235A material) is fixedly mounted on the mounting base 111 by three sets of second screws 2. Polyurethane rubber pads are installed on both sides of limiting component II 114, providing high hardness, high strength, wear resistance, and aging resistance. A rocker arm 11 (made of 45# steel) is fixedly mounted on the rotating shaft 12 by the pin 112 and a set of third screws 3. The rotating shaft 12 has through holes for connection with the rocker arm 11 and limiting component I 113. The mounting base 111 is fixedly mounted on the column I by eight sets of fourth screws 4. 7. A certain margin is left within the swing angle range required by the load simulation, which plays a good limiting role for the rocker arm 11 and the rotating shaft 12, limiting their swing angle range and protecting the product.

[0038] Both sides of the mounting base 111 have through holes, each housing a self-aligning roller bearing capable of automatic self-alignment and compensating for coaxiality errors. As a standard racking product, optimized selection ensures the spindle remains eccentric while maintaining precision and stability, thus improving dynamic balance. The bearing end caps are secured to one side of the mounting base using six sets of fifth screws 5. The mounting base is made of Q235A carbon structural steel, which possesses excellent plasticity and toughness, as well as good weldability and hot workability. It is machined as a whole, with the main holes formed in a single clamping operation, thereby enhancing the simulator's structural strength and coaxial layout.

[0039] Friction loading design is attached. Figure 3As shown, the friction loading mechanism includes an adjustable nut 41, a disc 42, washer a 43, a needle roller 44, washer b 45, a disc spring assembly 46, a spring shaft 47 (made of 45# steel for higher strength and resistance to deformation), a friction shaft 48 (made of brass for high strength, high hardness, and strong wear resistance), and a cage. Four sets of adjustable nuts 41 are mounted symmetrically on the disc 42 of the friction loading mechanism in a cross-shaped arrangement. The disc 42 is machined from Q235A steel and is fixed to the mounting base 111 by four sets of sixth screws 6. Washers a 43 and b are respectively mounted on both sides of the needle roller 44 and the cage. 45. A disc spring assembly 46 is installed on the outer side of washer b45. A spring shaft 47 is installed at one end of the disc spring assembly. Components 41, 43 to 46 are all mounted on the spring shaft 47. When the friction loading mechanism is activated, the clamping force is indirectly applied to the spring shaft through the adjustable nut 41. The clamping force is then transmitted from the spring shaft 47 to the friction shaft 48, ultimately pressing the friction plate onto the friction ring, thus achieving the loading and adjustment of the friction torque. Two protective covers protect the platform and the operator. These covers can move left and right for easy installation, adjustment, and maintenance. A lifting hole is also installed above the column for easy hoisting. See attached... Figure 3 .

[0040] Adjustable frictional torque, precise simulation: The adjustable frictional torque ranges from 0 to X Nm. This invention employs a 4-set friction plate loading method, adjusting the pressure applied to the friction plates by regulating the clamping force of the disc springs. The maximum frictional torque applied by each set of friction plates is X / 4. The radius of the friction plate loading axis is r, so the frictional force along the tangent is X / 4r. Assuming the coefficient of friction is μ, F_friction = F_pressure.μ, then the required normal force of the disc spring is X / 4rμ. This invention uses a parallel overlapping + straight combination method, stacking two disc springs side-by-side and combining five sets of parallel overlapping disc springs in a straight line. When the deformation is x, the clamping normal force is X / 4rμ, providing X / 4 of the frictional torque. The pitch of the clamping disc spring screw is P, so starting from when the friction plate just contacts the shaft, when tightened 360x / P degrees, the 4 sets of friction plates provide X Nm of frictional torque.

[0041] The connecting flange on the right side of the disc 42 (made of Q235A material) is mounted on the disc 42 by six sets of sixth screws 6 evenly distributed around the circumference. The base of the product encoder 6 at the far right end is mounted on the right side of the connecting flange by three sets of seventh screws 7 evenly distributed around the circumference. The main shaft is connected to the intermediate shaft of the product encoder 6 through a coupling.

[0042] The hinge torque loading design is attached. Figure 4As shown, the hinge torque adjustment mechanism includes an upper pressure plate 21, a lower pressure plate 22, an adjusting seat 23, a fixed seat 24, and a threaded plate 25 (all made of Q235A material). The hinge torque is simulated by a spring steel plate 10 (50CrV spring steel, which has good mechanical and technological properties, high fatigue strength, and high yield ratio). The effective clamping length of the spring steel plate 10 is adjusted by the "hinge torque adjustment mechanism" to meet the continuous adjustment of the loading torque within a certain range. Specifically, the positions of the upper pressure plate 21 and the lower pressure plate 22 on the adjusting seat 23 are adjusted and connected to the threaded plate 25 by four sets of first bolts 1. The adjusting seat 23 is installed on the fixed seat 24 by four sets of second bolts 2, and the fixed seat is installed and fixed on the column II by six sets of third bolts 3.

[0043] The stiffness-adjustable design is shown in the attached figure. Figure 5 Appendix Figure 6As shown, the stiffness adjustment mechanism includes a mounting base 11, clamping component I12, clamping component II13, upper support lug 14, and connecting plate 15. The clamping components I12 and II13 (made of 45# steel) on the parallel adjustable universal load simulator are adjusted to their positions on the upper support lug 14 (made of 45# steel) and the mounting base 11. Simultaneously, clamping components I12 and II13 are fixed to the connecting plate 15 (made of Q235A steel). Clamping components I12 and II13 are fixed to the mounting base 11 by four sets of fourth bolts 4. The mounting base 11 is made of Q235A steel and is fixed to the column I7 by four sets of fifth bolts 5, thereby improving static stiffness and structural strength. The mounting base 11 has rectangular grooves on both sides. To securely connect the clamping member I12 to these grooves, its side protrudes. Similarly, to securely connect the clamping member II13 to the upper support ear 14, one side of the clamping member II13 also protrudes to match the upper support ear 14. This allows adjustment of the effective extension length of the upper support ear 14, thus adjusting the product's installation stiffness. The load-bearing design is universal—installation stiffness is adjustable: the installation stiffness of this invention is adjustable from K1 to K2 N / m. With a loading torque of M and a rocker arm axis distance of r, the maximum force that the upper support ear can withstand is calculated to be M / r. In the simulation calculation, force M / r is selected. Within this stiffness range, the displacement range at the product pin is M / rK2 to M / rK1, which meets the usage requirements. This solution utilizes the adjustable mounting distances of clamping elements I12 and II13 on the upper support 14 and mounting base 11 to adjust the effective extension length of the upper support 14, thereby controlling the stiffness within the required range. This allows for simulation testing of the servo mechanism's performance under different mounting stiffness conditions. The load simulator is designed with interface modules for different models, and the servo mechanism connects to the load simulator through these modules. Traditional loads used in the development phase can only accommodate one type of servo mechanism, with a fixed mounting stiffness. This invention achieves universality between different models compared to traditional loads used in the development phase.

[0044] Appendix Figure 1 The inertia adjustment mechanism 3 uses a mechanical inertia disk to simulate and adjust inertial loads. The inertia plates are designed in a semi-circular ring shape, symmetrically mounted on the inertia disk by three sets of sixth bolts 6. Multiple sets of inertia plates are set. Based on the rated inertia value of the load simulator before the inertia plates are installed, the continuous loading of the simulated load is achieved within a certain range by combining the inertia plates. The expansion sleeve is mounted on the inertia disk by six sets of seventh bolts 7. The expansion sleeve cooperates with the clamping part in the inertia adjustment mechanism 3 to fix one end of the spring steel plate to the inner ring of the inertia adjustment mechanism by four sets of eighth bolts 8, and the other end is connected to the main shaft. The column I 7 is integrally machined from Q235A and fixed to the base plate by ten sets of ninth bolts 9 through screwing and welding. The base plate is also made of Q235A material to improve the overall static stiffness.

[0045] When using this load simulator, one end of the servo mechanism under test is mounted on the "stiffness adjustment mechanism" via a pin, and the other end is mounted on the rocker arm via a rocker arm pin. When the servo mechanism moves, it drives the rocker arm and the rotating shaft to swing.

[0046] The contents not described in detail in this specification are common knowledge to those skilled in the art.

[0047] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. A parallel adjustable universal load simulator, characterized in that, It includes column I, column II, protective cover, platform, and two primary sub-mechanisms; After the protective cover and the platform are connected, a cavity with an opening on one side is formed. Column II is located inside the cavity, and column I is located outside the cavity. The two primary submechanisms are identical and are mounted back-to-back on columns I and II; that is, a part of each primary submechanism is located inside the cavity. Each primary submechanism includes two secondary submechanisms and a stiffness adjustment mechanism; the two secondary submechanisms are arranged vertically and each is connected to one end of a servo product under test, and the two servo products under test are connected to the same stiffness adjustment mechanism; the stiffness adjustment mechanism simulates different installation stiffness by adjusting the effective extension length of its own lug, wherein the lug is connected to the servo product under test. Each secondary submechanism includes a limit protection mechanism, a hinge torque adjustment mechanism, an inertia adjustment mechanism, a friction loading mechanism, a product encoder, a spring steel plate, a rocker arm, and a rotating shaft. The other end of the servo product under test is connected to the rotating shaft via the rocker arm. The limit protection mechanism is mounted on column I to limit one end of the rotating shaft. The friction loading mechanism applies friction torque to the rotating shaft. The other end of the rotating shaft is limited by the hinge torque adjustment mechanism via the spring steel plate. The hinge torque adjustment mechanism simulates different hinge torques by adjusting the effective length of the spring steel plate. The inertia adjustment mechanism is mounted on the rotating shaft to simulate and adjust inertial loads. The product encoder measures the swing angle of the load simulator. The stiffness adjustment mechanism includes a mounting base, clamping element I, clamping element II, an upper support lug, and a connecting plate. Clamping elements I and II are both fixed to the connecting plate and connected to the mounting base. By adjusting the installation positions of clamping elements I and II on the upper support lug and the mounting base, the static stiffness and structural strength are improved. Rectangular grooves are provided on both sides of the mounting base. To fix clamping element I to the grooves of the mounting base, clamping element I has a protruding side. To fix clamping element II to the upper support lug, clamping element II has a protrusion on one side that matches the upper support lug, so as to adjust the effective extension length of the upper support lug. Each limit protection mechanism includes a mounting base, a pin, limit component I, and limit component II. Limit component II is fixedly connected to the mounting base, and limit component I is fixedly connected to the rotating shaft. When the rotating shaft swings, limit component I swings accordingly. The limit protection function is achieved by limiting the angle between the left and right ends of limit component II and limit component I. The friction loading mechanism is achieved by using multiple sets of disc springs in parallel overlapping and in a straight combination to load friction pairs; The friction loading mechanism includes an adjustable nut, a disc, a needle roller, a disc spring assembly, a spring shaft, a friction shaft, and a cage. The adjustable nut is mounted on the disc in a cross-symmetrical manner. The disc is fixed on the mounting base of the limit protection mechanism. The disc spring assembly is mounted on one side of the needle roller and the cage. The adjustable nut, needle roller, and disc spring assembly are all mounted on the spring shaft. Each primary submechanism has two workstations, one above the other. The two secondary submechanisms can adjust the stiffness of the two tested servo products through a stiffness adjustment mechanism. The two primary submechanisms located back-to-back on both sides of column I form four workstations.

2. The parallel adjustable universal load simulator according to claim 1, characterized in that, Each secondary sub-unit also includes a control driver interface module for adapting to the servo product under test.

3. The parallel adjustable universal load simulator according to claim 1, characterized in that, The product encoder is concentric with the rotating shaft. When the rocker arm and the rotating shaft swing, the product encoder provides feedback on the swing angle.

4. The parallel adjustable universal load simulator according to claim 1, characterized in that, The hinge torque adjustment mechanism includes an upper pressure plate, a lower pressure plate, an adjusting seat, a fixed seat, and a threaded plate; the position of the upper pressure plate and the lower pressure plate on the adjusting seat is adjusted, the adjusting seat is installed on the fixed seat, and the fixed seat is installed and fixed on column II.

5. The parallel adjustable universal load simulator according to any one of claims 1 to 4, characterized in that, When using this load simulator, one end of the servo mechanism under test is mounted on the stiffness adjustment mechanism via a pin, and the other end is mounted on the rocker arm via a rocker arm pin; when the servo mechanism moves, it drives the rocker arm and the rotating shaft to swing.

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