Automatic coupling device of test bench drive shaft and automatic coupling adjustment method

Abstract

The application discloses a kind of loading test bench drive shaft automatic combination device and adjusting method, belong to detection equipment technical field, drive shaft automatic combination device includes electromagnetic clutch assembly, electromagnetic clutch assembly includes driving part, driven part, driving ring gear part, driven ring gear part, position sensor and torque loading assembly;Driving ring gear part is installed in driving part;Driven ring gear part is installed in driven part;Driving ring gear part and driven ring gear part are equipped with the ring gear tooth part of adaptation;Position sensor is set in the axial side of driving ring gear part or driven ring gear part;Torque loading assembly is connected with driving part and loads torsion to driving part, and torque loading assembly is connected with position sensor.This loading test bench drive shaft automatic combination device has static automatic combination mode and adjustment function, with the remarkable effect of optimizing transmission performance, improving test efficiency, enhancing reliability and improving precision.

Description

Technical Field

[0001] This invention belongs to the technical field of speed reducer and gearbox testing equipment, and particularly relates to an automatic engagement device for the transmission shaft of a high-precision high-torque loading test bench and an automatic engagement adjustment method. Background Technology

[0002] Gear reducers and transmissions play a vital role in the mechanical field, essential for transmitting power and changing speed and torque. A gear reducer is a device used to reduce the high-speed rotation of an input shaft, converting high-speed rotation into low-speed, high-torque rotation through gear transmission. A transmission is a device that can change the speed of the output shaft, allowing users to adjust the speed of the drive system as needed. Load testing is essential before manufacturing gear reducers and transmissions. These tests aim to verify that their design and performance meet specifications and requirements. Load testing involves applying specific loads to the gear reducer or transmission to simulate the working loads in real-world operating environments. This ensures that they can operate stably in practical applications and withstand corresponding pressures and loads. The tests can also detect any potential problems or defects, allowing for necessary adjustments and improvements. By conducting load testing, manufacturers can guarantee the quality and reliability of their products and ensure that they meet the expected performance levels before leaving the factory.

[0003] The torque loading device used in the test is connected to the reducer or gearbox via a drive shaft. Existing performance loading test equipment for reducers or gearboxes typically lacks an automatic drive shaft engagement function. To achieve automatic drive shaft engagement, an electromagnetic clutch is often connected in series between the output and input shafts. During the installation of the reducer or gearbox under test, the electromagnetic clutch is disengaged, allowing the output shaft to move freely, facilitating the installation of the test piece. During testing, the electromagnetic clutch engages, connecting the output and input shafts as a single unit. Dog clutches have the advantages of small size and high torque transmission, and are therefore widely used in high-torque load transmission applications. However, dog clutches present some problems when applied to high-torque load test benches. They require relatively low speeds to engage. During low-speed engagement, if the transmission teeth of the dog clutch do not engage properly, impacts may occur, causing tooth wear. These impacts can also adversely affect the entire mechanical system, impacting the accuracy of the test results. Furthermore, there may be angular misalignment between the input and output shafts during engagement of the dog clutch. This misalignment can lead to imbalance and vibration in the transmission system, thus affecting the performance and stability of the loading test bench. Furthermore, angular misalignment increases wear and noise in the gear transmission, reducing the overall system reliability.

[0004] Due to the aforementioned problems, existing dog clutch engagement devices and control methods can no longer meet the demands of current automated testing systems for components such as high-precision, high-torque vibration dampers and gearboxes. Therefore, it is necessary to design a drive shaft device with automatic engagement function to meet the automated testing requirements of today's high-precision, high-torque loading test benches. Summary of the Invention

[0005] To address the problems existing in the prior art, this invention provides an automatic engagement device and automatic engagement adjustment method for the transmission shaft of a loading test bench, which solves problems such as low-speed engagement, incomplete engagement causing impact, tooth wear, and input / output shaft angle deviation of the toothed electromagnetic clutch during loading tests.

[0006] This invention is implemented as follows: an automatic engagement device for the drive shaft of a loading test bench, comprising an electromagnetic clutch assembly, the electromagnetic clutch assembly including an active component and a driven component, characterized in that it includes an active ring gear component, a driven ring gear component, a position sensor, and a torque loading assembly; the active ring gear component is mounted on the active component; the driven ring gear component is mounted on the driven component; wherein, the active ring gear component and the driven ring gear component are provided with matching ring tooth teeth, and the electromagnetic clutch assembly electromagnetically controls the two ring tooth teeth to axially approach each other; the position sensor is disposed on the axial side of the axially moving active ring gear component or driven ring gear component, and the position sensor is used to detect the axial position of the ring tooth teeth; the torque loading assembly is connected to the active component and applies torque to the active component, and the torque loading assembly is connected to the position sensor.

[0007] In the above technical solution, preferably, the active component is equipped with an angle sensor for detecting the transmission angle of the active component, and the angle sensor is connected to the torque loading component.

[0008] In the above technical solution, preferably, the active component includes a drive shaft and an active rotating body connected to the drive shaft; the driven component includes a driven shaft and a driven rotating body connected to the driven shaft; the active ring gear component is mounted on the active rotating body; the driven ring gear component is mounted on the driven rotating body; the active rotating body and / or the driven rotating body is mounted on an electromagnetic drive unit that moves axially by electromagnetic control; the active ring gear component and / or the driven ring gear component is mounted on the electromagnetic drive unit; the torque loading component is connected to the drive shaft and loads torque onto the drive shaft; and the angle sensor is mounted on the drive shaft.

[0009] In the above technical solution, preferably, the torque loading assembly includes an electric cylinder and a push rod. The lower part of the electric cylinder is mounted on a shaft seat. The piston rod of the electric cylinder is hinged to one end of the push rod via a pin. The other end of the push rod is connected to the drive shaft. The axis of the pin and the shaft seat is parallel to the axis of the drive shaft.

[0010] In the above technical solution, preferably, the position sensor is connected to the controller, the electric cylinder includes a servo motor that drives the piston rod of the electric cylinder, and the controller controls the servo motor to output test torque through the signal from the position sensor; the angle sensor is connected to the controller, and the controller controls the servo motor to drive the drive shaft to rotate by a compensation angle α through the signal from the angle sensor.

[0011] The advantages and effects of this invention are:

[0012] 1. Static Automatic Engagement: Electromagnetic clutches employing static automatic engagement can achieve stable and reliable engagement operation. Compared to traditional low-speed engagement methods, static automatic engagement eliminates the impact and wear caused by low-speed rotation, improving the reliability and service life of the transmission system.

[0013] 2. Adjustment Function: The device features an adjustment function, allowing the electromagnetic clutch to be adjusted according to actual needs. This adjustment ensures reliable engagement of the electromagnetic clutch before each test, avoiding issues such as incomplete engagement and input / output shaft angle misalignment. This flexibility enables the device to adapt to the requirements of different loading test benches, providing stable and accurate transmission performance.

[0014] 3. Problem Avoidance: By optimizing the engagement method of the electromagnetic clutch, the device can avoid a series of problems caused by low-speed engagement. The risk of impact and tooth wear is reduced, decreasing the cost of maintenance and replacement of transmission components. Simultaneously, the device's design helps eliminate angular misalignment between the input and output shafts, reducing vibration and noise generation, and improving the stability and accuracy of the loading test bench.

[0015] 4. Improved Testing Efficiency: The device's static automatic engagement mode and adjustable function ensure reliable engagement of the electromagnetic clutch before each test. This shortens test preparation time, improves testing efficiency, and allows the loading test bench to begin testing more quickly, thereby increasing production efficiency and product development progress.

[0016] 5. Enhanced Transmission System Reliability: By eliminating the impact and wear caused by low-speed engagement, the device is expected to extend the service life of transmission components and reduce the need for maintenance and replacement. This will improve the reliability and stability of the loading test bench and reduce operating costs.

[0017] 6. Improved Testing Accuracy: The device avoids problems such as misalignment and angular deviation, helping to improve the precision and accuracy of the loading test bench. Test results will be more reliable and consistent, providing more accurate data support for product design and performance evaluation.

[0018] In summary, this automatic engagement device for the drive shaft of the loading test bench solves the problems of the jaw-type electromagnetic clutch in loading tests through static automatic engagement and adjustment functions. It significantly optimizes transmission performance, improves testing efficiency, enhances reliability, and increases accuracy. This technical solution has significant application value and economic benefits in the field of loading testing.

[0019] Another objective of this invention is to provide an automatic engagement adjustment method for the drive shaft using the aforementioned automatic engagement device for the drive shaft of a loading test bench, characterized by the following steps:

[0020] S1. The electromagnetic clutch assembly controls the axial movement of the active ring gear component and the driven ring gear component;

[0021] S2. The position sensor detects the axial position information of the active ring gear component and the driven ring gear component, and determines whether the active ring gear component and the driven ring gear component are engaged based on the axial position information;

[0022] S3. The position sensor sends information to the servo motor of the torque loading component based on the engagement state of the active ring gear component and the driven ring gear component;

[0023] S3. The servo motor of the torque loading component selects the working mode according to the engagement state of the active ring gear component and the driven ring gear component. When the active ring gear component and the driven ring gear component are not engaged, the electromagnetic clutch component controls the axial component force of the active ring gear component and the driven ring gear component. After the servo motor drives the active component to rotate by the compensation angle α, steps S1-S4 are repeated. When the active ring gear component and the driven ring gear component are engaged, the servo motor outputs the test loading torque to the active component.

[0024] In the above technical solution, preferably, a delay time interval t1 is set between step S1 and step S2.

[0025] In the above technical solution, preferably, in step S3, a time interval t2 is set between the axial component force of the electromagnetic clutch component controlling the active ring gear component and the driven ring gear component and the rotation compensation angle α of the servo motor driving the active component.

[0026] In the above technical solution, preferably, the line connecting the center of the tooth tip of the annular tooth portion and the center of the annular tooth portion is L1, the line connecting the center of the tooth root of the annular tooth portion and the center of the annular tooth portion is L2, and the included angle between L1 and L2 is the compensation angle α. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the present invention;

[0028] Figure 2 This is a side view of the present invention;

[0029] Figure 3 This is a flowchart illustrating the automatic combination and adjustment method in this invention;

[0030] Figure 4 This is a schematic diagram showing the state of the active ring tooth component and the driven ring tooth component before they are combined in this invention;

[0031] Figure 5 This is a schematic diagram of the structure in this invention where the active ring tooth component and the driven ring tooth component are not properly engaged.

[0032] Figure 6 This is a schematic diagram of the structure in which the active ring tooth component and the driven ring tooth component are joined together in this invention. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0034] To address the problems of low-speed engagement, incomplete engagement causing impact, tooth wear, and input / output shaft angular misalignment in jaw-type electromagnetic clutches during loading tests, this invention provides an automatic engagement device for the drive shaft of a loading test bench. This device achieves reliable engagement, avoids impact wear, and eliminates angular misalignment through static automatic engagement and adjustment functions, thereby improving testing efficiency, enhancing reliability, and increasing accuracy. For further explanation of the structure of this invention, a detailed description is provided below with reference to the accompanying drawings:

[0035] Please see Figure 1 and Figure 2 An automatic engagement device for the drive shaft of a loading test bench includes an electromagnetic clutch assembly, an active ring gear component 1, a driven ring gear component 2, a position sensor 3, an angle sensor, and a torque loading assembly 4.

[0036] Electromagnetic clutch assemblies are known transmission devices widely used in various mechanical systems. They consist of an electromagnetic component and a clutch component, using electromagnetic principles to connect and disconnect the drive shaft. An electromagnetic clutch assembly includes a driving component and a driven component. The driving ring gear component is mounted on the driving component, and the driven ring gear component is mounted on the driven component. Specifically, the driving and driven ring gear components are gear ring components that rotate around an axis, with matching trapezoidal teeth on one side of their annular end faces. The engagement and disengagement of the electromagnetic clutch assembly are achieved through the meshing and disengagement of these trapezoidal teeth.

[0037] In this embodiment, the driving component includes a driving shaft 5 and a driving rotary body 6 connected to the driving shaft, and the driven component includes a driven shaft 7 and a driven rotary body 8 connected to the driven shaft. A driving ring gear component is mounted on the driving rotary body, and a driven ring gear component is mounted on the driven rotary body. The driving rotary body and / or the driven rotary body are equipped with an electromagnetically controlled axially moving electromagnetic drive, and the driving ring gear component and / or the driven ring gear component are mounted on the electromagnetic drive. Specifically, in this embodiment, the driving ring gear component is directly mounted on the driving rotary body, the driven rotary body is equipped with an electromagnetically controlled axially moving electromagnetic drive, and the driven ring gear component is mounted on the electromagnetic drive. The electromagnetic drive is electromagnetically controlled to move axially, causing the driven ring gear component to axially approach or move away from the driving ring gear component for engagement or disengagement. The above-mentioned electromagnetic clutch assembly and the driving and driven ring gear components mounted thereon constitute a jaw-type electromagnetic clutch structure. As known to those skilled in the art, in an electromagnetic clutch assembly, the electromagnetic component typically consists of an electromagnetic coil and an electromagnet. When current flows through the electromagnetic coil, the generated magnetic field attracts the electromagnetic drive component, causing the driving and driven annular gear components to mesh. When the current stops flowing or reverses, the electromagnet loses its magnetic force, the electromagnetic drive component moves in the opposite direction, and the driving and driven annular gear components disengage, breaking the transmission. Specifically, the driving and driven annular gear components have matching annular tooth teeth, and the electromagnetic clutch assembly uses electromagnetic control to bring the two annular tooth teeth axially closer together. The electromagnetic clutch assembly is controlled by a controller to switch on and off.

[0038] An angle sensor for detecting the transmission angle of the active component is mounted on the active component, and the angle sensor is connected to the torque loading assembly. Specifically, in this embodiment, the angle sensor is mounted on the drive shaft. An angle sensor is a device used to measure the rotation angle of an object or system. It converts rotational mechanical motion into an electrical signal output to provide accurate information about the angular position. Commonly known angle sensors include rotary potentiometers, photoelectric encoders, Hall effect sensors, and magnetic sensors. These sensors use different principles, such as resistance changes, photoelectric effects, Hall effects, and magnetic field changes, to measure the angle of a rotating shaft. The angle sensor is mounted directly on the rotating shaft. This can be achieved by tightly connecting the sensor's mounting bracket or clamping device to the rotating shaft. The sensor's measuring element (such as a rotary potentiometer or encoder disk) is mounted concentrically with the rotating shaft to ensure that the sensor can accurately measure the rotation angle of the shaft.

[0039] The position sensor is positioned on the axial side of the axially moving active or driven ring gear component, and is used to detect the axial position of the ring gear teeth.

[0040] The torque loading assembly is connected to the active component and applies torque to it. The torque loading assembly is also connected to a position sensor. Specifically, the torque loading assembly is connected to the drive shaft and applies torque to it. In this embodiment, the torque loading assembly includes an electric cylinder 9 and a push rod 10. The lower part of the electric cylinder is mounted on a shaft seat 11. The piston rod of the electric cylinder is hinged to one end of the push rod via a pin. The other end of the push rod is connected to the drive shaft. The axis of the pin and the shaft seat is parallel to the axis of the drive shaft. A bushing 12 is mounted on the drive shaft via a key, and the end of the push rod is welded to this bushing. The electric cylinder includes a servo motor 13 that drives the piston rod of the electric cylinder.

[0041] A position sensor is connected to a controller, which uses the signal from the position sensor to control the servo motor to output applied torque to the drive shaft. An angle sensor is also connected to the controller, which uses the signal from the angle sensor to control the servo motor to drive the drive shaft to rotate by a compensation angle α. The rotation angle information of the drive shaft is acquired by adding an angle sensor coaxially to the drive shaft, resulting in more accurate angle measurements. The jaw clutch uses a static automatic engagement method and also has an adjustment function, ensuring reliable engagement of the jaw clutch before each test. This avoids the impact, tooth wear, and angular misalignment of the input and output shafts caused by the low-speed engagement of traditional jaw clutches.

[0042] The working principle of this device is:

[0043] This high-precision, high-torque loading test bench uses a servo motor to drive the piston rod of an electric cylinder to extend and retract. The extension and retraction of the piston rod causes a push rod to swing, which in turn drives the drive shaft to rotate, providing a large torque to the loading system. Compared to traditional loading methods that use hydraulic cylinders as the power source, this system offers advantages such as no oil leakage, no pollution, and low noise. Compared to existing technologies that use servo motors and reducers as the power source, this system offers advantages such as smaller size, higher torque, and smaller rotational backlash.

[0044] For the combination of electromagnetic clutch components, driving ring gear components, and driven ring gear components, a dog clutch is directly selected. The driving shaft is the transmission input shaft that connects the driving end of the dog clutch to the push rod, and the driven shaft is the transmission output shaft that connects the driven end of the dog clutch to it.

[0045] The flowchart of the specific adjustment method is shown in Figure 3, including:

[0046] 1. The electromagnetic clutch assembly controls the axial movement of the driving and driven ring gear components:

[0047] Before the loading test, the states of the driving and driven ring gear components are as follows: Figure 4 Before the loading test, the driving end of the jaw clutch and the driven end of the jaw clutch must be reliably engaged, that is, the driving ring gear component and the driven ring gear component must be reliably meshed. The controller energizes the jaw clutch, that is, the jaw clutch receives the shaft engagement command. The driving ring gear component and the driven ring gear component move closer together. Since the teeth of the driving ring gear component and the driven ring gear component are trapezoidal, after engagement, there is a situation where the teeth of the driving ring gear component and the driven ring gear component touch the teeth.

[0048] 2. The position sensor detects the axial position information of the driving and driven ring gear components, and sends information to the servo motor based on the axial position information of the driving and driven ring gear components:

[0049] When the driving and driven annular gear components are not fully engaged, i.e., when the teeth are at their tips, the engagement device is not fully engaged. Figure 6 As shown. The driven ring gear component, acting as an axial moving part, has a small positional offset. The position sensor located to its side, used to detect its axial position, does not detect the positional change of the driven ring gear component as reaching the set value, and therefore does not send a signal to the controller to control the servo motor to output the applied torque. When the driving and driven ring gear components are engaged, and the teeth of the driving end of the jaw clutch and the driven end of the jaw clutch correspond to each other in the top groove, this engagement device is in place, as shown. Figure 5As shown, the driven ring gear component, which is an axial moving component, has a large positional offset. When the position sensor located to its side detects the positional change of the driven ring gear component and reaches the set value, the position sensor sends a signal to the controller to control the servo motor to output the applied torque.

[0050] 3. The controller controls the operation of the torque loading component through signals from the position sensor:

[0051] After the controller powers on the jaw clutch, it controls the operation of the torque loading component via a signal from the position sensor after a delay of t1 (jaw clutch engagement time). If the engagement is successful, the servo motor in the torque loading component outputs loading torque, and the device performs a torque loading test. If the engagement is unsuccessful, the controller de-energizes the jaw clutch. After a delay of t2 (jaw clutch disengagement time), the driving end and driven end of the jaw clutch are completely disengaged. The controller then controls the servo motor in the torque loading component to drive the drive shaft to rotate by a certain angle, i.e., the piston rod of the electric cylinder is extended by the servo motor, controlling the driving end of the jaw clutch to rotate by a certain angle α. α is used as a compensation angle, and its angle value is set as the angle between the teeth and grooves of the driving and driven ring gear components. After rotating the compensation angle, the tooth profiles of the driving and driven ring gear components correspond. The controller then re-energizes the jaw clutch. After a delay of t1, the proximity switch detects whether the driving and driven ring gear components of the jaw clutch are engaged. At this point, the driving end and driven end of the jaw clutch are engaged.

[0052] Furthermore, after the driving end of the jaw clutch rotates by a certain compensation angle and attempts to engage again, if the position sensor detects that the position of the driving ring gear component and the driven ring gear component is still not in the engaged state, the connected controller will issue a fault signal.

[0053] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automatic engagement device for the drive shaft of a loading test bench, comprising an electromagnetic clutch assembly, wherein the electromagnetic clutch assembly includes a driving component and a driven component, characterized in that... include: An active ring gear component, wherein the active ring gear component is mounted on the active component; Driven ring gear component, the driven ring gear component is mounted on the driven component; The active ring tooth component and the driven ring tooth component are provided with matching ring tooth teeth, and the electromagnetic clutch assembly brings the two ring tooth teeth axially closer together through electromagnetic control. A position sensor is disposed on the axial side of the axially moving active or driven ring gear component, and the position sensor is used to detect the axial position of the ring gear teeth. A torque loading component, which is connected to the active component and applies torque to the active component, and is also connected to the position sensor; The active component is equipped with an angle sensor for detecting the transmission angle of the active component, and the angle sensor is connected to the torque loading component. The active component includes a drive shaft and an active rotating body connected to the drive shaft; the torque loading component is connected to the drive shaft and loads torque onto the drive shaft. The torque loading assembly includes an electric cylinder and a push rod. The lower part of the electric cylinder is mounted on a bearing seat. The piston rod of the electric cylinder is hinged to one end of the push rod via a pin. The other end of the push rod is connected to the drive shaft. The axis of the pin and the bearing seat is parallel to the axis of the drive shaft. The position sensor is connected to the controller, and the electric cylinder includes a servo motor that drives the piston rod of the electric cylinder. The controller controls the servo motor to output test torque through the signal from the position sensor. The angle sensor is connected to the controller, and the controller controls the servo motor to drive the drive shaft to rotate by a compensation angle α through the signal from the angle sensor.

2. The automatic engagement device for the drive shaft of the loading test bench according to claim 1, characterized in that: The driven component includes a driven shaft and a driven rotating body connected to the driven shaft; the driving ring gear component is mounted on the driving rotating body, the driven ring gear component is mounted on the driven rotating body, the driving rotating body and / or the driven rotating body is mounted on an electromagnetic drive unit for electromagnetically controlled axial movement, and the driving ring gear component and / or the driven ring gear component is mounted on the electromagnetic drive unit; the angle sensor is mounted on the driving shaft.

3. A method for automatically adjusting the transmission shaft using the automatic transmission shaft engagement device of the loading test bench as described in claim 1 or 2, characterized in that... Includes the following steps: S1. The electromagnetic clutch assembly controls the axial movement of the active ring gear component and the driven ring gear component; S2. The position sensor detects the axial position information of the active ring gear component and the driven ring gear component, and determines whether the active ring gear component and the driven ring gear component are engaged based on the axial position information; S3. The position sensor sends information to the servo motor of the torque loading component based on the engagement state of the active ring gear component and the driven ring gear component; S3. The servo motor of the torque loading component selects the working mode according to the engagement state of the active ring gear component and the driven ring gear component. When the active ring gear component and the driven ring gear component are not engaged, the electromagnetic clutch component controls the axial component force of the active ring gear component and the driven ring gear component. After the servo motor drives the active component to rotate by the compensation angle α, steps S1-S4 are repeated. When the active ring gear component and the driven ring gear component are engaged, the servo motor outputs the test loading torque to the active component.

4. The automatic coupling adjustment method according to claim 3, characterized in that: A delay time interval t1 is set between step S1 and step S2.

5. The automatic coupling adjustment method according to claim 4, characterized in that: In step S3, a time interval t2 is set between the axial component force of the electromagnetic clutch component controlling the active ring gear component and the driven ring gear component and the rotation compensation angle α of the active component driven by the servo motor.

6. The automatic combination adjustment method according to claim 5, characterized in that: The line connecting the center of the tooth tip of the annular tooth portion and the center of the annular tooth portion is L1, and the line connecting the center of the tooth root of the annular tooth portion and the center of the annular tooth portion is L2. The included angle between L1 and L2 is the compensation angle α.

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