Electric power steering system integrated machine airtightness test tool and test method

Abstract

The application discloses an air tightness test tool for an electric power steering system integrated machine, which comprises a connector sealing assembly for sealing all connectors and air valves on the integrated machine and an air inlet positioning sealing assembly for being installed on the integrated machine and for conveying gas into the integrated machine during the test process, the connector sealing assembly comprises a whole vehicle sheath wire harness and a power supply sheath wire harness, and the whole vehicle sheath wire harness and the power supply sheath wire harness are arranged to be connected with a program burning device and the connectors on the integrated machine when the integrated machine is programmed and burned during the test process. The air tightness test tool for the electric power steering system integrated machine can integrate the air tightness test and the program burning into one process, reduces process beat time and personnel waste, and improves production efficiency; the tool structure is simple and compact, the manufacturing cost is low, and the dismounting process is time-saving and labor-saving. The application further discloses an air tightness test method for the electric power steering system integrated machine.

Description

Technical Field

[0001] This invention belongs to the technical field of vehicle steering system testing and inspection equipment. Specifically, this invention relates to an airtightness testing fixture and testing method for an integrated electric steering system. Background Technology

[0002] An integrated motor unit is an electrical component that structurally integrates a brushless motor and an ECU (Electronic Control Unit). It is a crucial safety electrical component in electric power steering systems, combining control and execution. The integrated motor unit of an electric power steering system mainly consists of a brushless motor, PCBA assembly, ECU base, ECU cover, vent valve, O-ring seals, screws, and other parts. Its structure is compact, highly integrated, and occupies little space. It eliminates the wiring harness connecting the motor and ECU, facilitating the overall vehicle layout of the electric power steering system. It also features excellent modularity, allowing for the replacement of brushless motors with different torque requirements to expand the maximum output or torque needed in a vehicle. This convenient switching reduces product development and manufacturing costs.

[0003] like Figure 25 The diagram shows the integrated unit's structure. The integrated unit's structure provides a certain level of protection within the electric power steering system. Its purpose is to effectively prevent water, mud, dust, and other foreign objects from entering and damaging components when the vehicle encounters water, mud, dust, or other foreign objects during driving, thus ensuring the integrated unit's normal operation. To effectively test whether the integrated unit possesses this protective capability, an airtightness test is conducted to measure its effectiveness. Current airtightness testing fixtures for integrated units involve plugging the removed vent valve hole with a plug, then sealing the power connector, sensor signal connector, and vehicle signal connector on the integrated unit with a power supply sleeve, sensor sleeve, and vehicle signal connector, respectively. Finally, three bolts are passed through the three mounting holes on the integrated unit and secured to the threaded holes on the air intake base. The equipment's test button is then pressed to perform three test processes: air intake, pressure holding, and testing. After the air tightness test is completed, first unscrew the three bolts locked on the air intake base, then remove the power supply cover, sensor cover, and vehicle cover respectively, and finally unscrew the plug and screw on the vent valve.

[0004] After the all-in-one unit passes the airtightness test, the product application programming process begins. This requires connecting the power sheathed harness and the vehicle signal sheathed harness to the power connector and vehicle signal connector on the all-in-one unit, respectively. Then, press the "Start Programming" button on the computer program interface. The computer will complete the program programming of the all-in-one unit according to the set program. After programming is complete, the power sheathed harness and vehicle signal sheathed harness are removed. Because the space between the power connector and the vehicle signal connector on the all-in-one unit is very narrow, it is very inconvenient to remove them manually. Furthermore, the internal terminals connecting the connectors require considerable pulling force to detach, making it even more difficult to disconnect the power sheathed harness and vehicle signal sheathed harness.

[0005] The airtightness testing fixture and program burning method for the all-in-one machine described above involves two processes in its production, which increases the cycle time and reduces work efficiency. The main problems are as follows:

[0006] 1. Two processes result in wasted manpower, increased process cycle time, and reduced production efficiency.

[0007] 2. The space between the power supply sleeve, sensor sleeve, and vehicle sleeve is small, making it time-consuming and laborious to remove the sleeves, resulting in low work efficiency.

[0008] 3. The airtightness test fixture relies on manual disassembly and assembly of bolts and parts, which is cumbersome, time-consuming, and inefficient. Summary of the Invention

[0009] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, the present invention provides an airtightness testing fixture for an integrated electric power steering system, with the purpose of improving the production efficiency of integrated electric power steering systems.

[0010] To achieve the above objectives, the technical solution adopted by the present invention is as follows: an airtightness testing fixture for an integrated electric power steering system, comprising a connector sealing assembly for sealing all connectors and vent valves on the integrated unit, and an air intake positioning sealing assembly for being installed on the integrated unit and for supplying gas into the integrated unit during the test. The connector sealing assembly includes a vehicle sheath wiring harness and a power supply sheath wiring harness, which are configured to connect the program burning device and the connectors on the integrated unit when the integrated unit is programmed during the test.

[0011] The connector sealing assembly further includes a sheath positioning block, a sensor sheath and a pressure sleeve disposed on the sheath positioning block, and a first quick-change clamp assembly for applying pressure to the sheath positioning block. The vehicle sheath wiring harness and the power sheath wiring harness are disposed on the sheath positioning block. The vehicle sheath wiring harness is connected to the vehicle signal connector of the integrated unit, and the power sheath wiring harness is connected to the power connector of the integrated unit. The pressure sleeve is configured to seal the vent valve.

[0012] The sheath positioning block is provided with a vehicle sheath positioning hole, a power supply sheath positioning hole and a sensor sheath positioning hole. The vehicle sheath wiring harness is installed in the vehicle sheath positioning hole, the power supply sheath wiring harness is installed in the power supply sheath positioning hole, and the sensor sheath is installed in the sensor sheath positioning hole.

[0013] The sheath positioning block is connected to the push rod of the first quick-change clamp assembly via an adjusting screw. The adjusting screw is fixed to the sheath positioning block by a nut, and the nut and the adjusting screw are threaded together. The distance between the sheath positioning block and the first quick-change clamp assembly is adjustable.

[0014] The air intake positioning and sealing assembly includes a clamp positioning block, a second quick-change clamp assembly disposed on the clamp positioning block, an air intake positioning sleeve connected to the clamp positioning block and used for mounting on the integrated machine, and an air intake pressure sleeve connected to the push rod of the second quick-change clamp assembly and used for cooperating with the integrated machine to form an air intake sealing cavity. An air intake pipe is disposed on the air intake pressure sleeve, and the air intake pipe communicates with the air intake sealing cavity.

[0015] The air intake sleeve is provided with a first countersunk hole and a second countersunk hole. A sealing ring for contacting the integrated machine is provided in the first countersunk hole. The diameter of the first countersunk hole is smaller than the outer diameter of the sealing ring. The air intake pipe is connected to the second countersunk hole.

[0016] The intake pressure sleeve is disposed in the central hole of the intake positioning sleeve, and the intake pressure sleeve can move axially relative to the intake positioning sleeve.

[0017] The air intake positioning sleeve is provided with a first hook positioning surface, a second hook positioning surface, and a third hook positioning surface that correspond to the shape of the three-claw mounting surface of the first mounting hole, the second mounting hole, and the third mounting hole on the integrated machine. Positioning holes for inserting positioning pins are provided at the first hook positioning surface, the second hook positioning surface, or the third hook positioning surface. The positioning pins contact and limit the hole positioning surface on the integrated machine.

[0018] The airtightness testing fixture for the integrated electric steering system also includes a slider connected to the connector sealing assembly and the clamp positioning block, and the axial position of the connector sealing assembly is adjustable.

[0019] This invention provides a method for airtightness testing of an integrated electric steering system, employing the aforementioned airtightness testing fixture, and comprising the following steps:

[0020] S1. Take the integrated testing and inspection machine;

[0021] S2. Air tightness testing fixture for integrated positioning electric steering system;

[0022] S3, Clamping of the connector and the air intake positioning seal;

[0023] S4. Conduct an airtightness test and program burning;

[0024] S5. Remove the integrated machine that has completed the airtightness test and program burning.

[0025] The airtightness testing fixture for the integrated electric steering system of the present invention can integrate the two processes of airtightness testing and program burning into one process, reducing process cycle time and personnel waste, and improving production efficiency. The fixture has a simple structure and low manufacturing cost, and the disassembly and assembly process is time-saving and labor-saving. The disassembly and assembly process of airtightness testing and burning is highly efficient and more convenient and reliable. The disassembly and assembly process of testing and burning can be completed by simply loosening or clamping the quick-change clamp assembly on the fixture. Attached Figure Description

[0026] This manual includes the following figures, which illustrate the following:

[0027] Figure 1 This is a schematic diagram of the integrated machine airtightness testing fixture structure;

[0028] Figure 2 This is an exploded view of the assembly of parts for the airtightness test fixture of the integrated machine;

[0029] Figure 3 This is the main view of the integrated machine airtightness testing fixture;

[0030] Figure 4 This is a top view of the integrated machine's airtightness testing fixture;

[0031] Figure 5 yes Figure 4 Sectional view of AA;

[0032] Figure 6 yes Figure 4 BB section view;

[0033] Figure 7 This is a schematic diagram of the intake positioning sleeve structure;

[0034] Figure 8 This is the main view of the air intake positioning sleeve;

[0035] Figure 9 yes Figure 8 CC section view;

[0036] Figure 10 yes Figure 9 Middle left view;

[0037] Figure 11 This is a schematic diagram of the sheath positioning block structure;

[0038] Figure 12 This is the main view of the sheath positioning block;

[0039] Figure 13 yes Figure 12 DD section view;

[0040] Figure 14 This is a schematic diagram of an L-shaped slider structure;

[0041] Figure 15 This is a partial sectional view of the L-shaped slider;

[0042] Figure 16 This is a schematic diagram of the clamp positioning block structure;

[0043] Figure 17 This is a partial sectional view of the clamp positioning block;

[0044] Figure 18 yes Figure 17 Right view of the clamp positioning block;

[0045] Figure 19 This is the main view of the locking sleeve;

[0046] Figure 20 This is a top view of the locking sleeve;

[0047] Figure 21 This is a schematic diagram of the pressure sleeve structure;

[0048] Figure 22 This is a sectional view of the pressure sleeve;

[0049] Figure 23 This is a schematic diagram of the intake manifold structure;

[0050] Figure 24 This is a cross-sectional view of the intake manifold;

[0051] Figure 25 This is a schematic diagram of the all-in-one machine structure;

[0052] Figure 26 This is the main view of the all-in-one machine;

[0053] The diagram is marked as follows:

[0054] 1. Vehicle wiring harness; 2. Power supply wiring harness; 3. First O-ring seal; 4. Pressure sleeve; 5. Sensor sleeve; 601. Sleeve positioning block; 602. Vehicle wiring harness positioning hole; 603. Sensor sleeve positioning hole; 604. Limiting hole; 605. Power supply sleeve positioning hole; 7. Hex socket head cap screw; 8. Locking nut; 9. First hex nut; 10. Second hex nut; 11. Adjusting screw; 12. Third hex nut; 13. ... 14. Fifth hexagonal nut; 1501. Slider; 1502. First sliding groove; 1503. Second sliding groove; 1504. Concave groove; 16. First quick-change clamp assembly; 17. First internal hex bolt; 1801. Clamp positioning block; 1802. First positioning hole; 1803. Second positioning hole; 1804. Convex slider; 19. First positioning pin; 20. Second quick-change clamp assembly; 21. Second positioning pin; 22. Second hex socket head cap screw; 23. Third hex socket head cap screw; 24. Sixth hex nut; 2501. Inlet positioning sleeve; 2502. First hook positioning surface; 2503. Third hook positioning surface; 2504. Second hook positioning surface; 2505. Third positioning hole; 2506. Fourth positioning hole; 2507. Fifth positioning hole; 26. Third positioning pin; 27. Seventh hex nut; 28. Inlet pipe; 29. ​​Eighth hex nut; 30. Locking sleeve 31. Air pipe connector; 32. Fourth hex bolt; 33. Air inlet sleeve; 34. Second O-ring seal; 3501. Integrated unit; 3502. First mounting hole; 3503. Stop seal end face; 3504. Second mounting hole; 3505. Sensor signal connector; 3506. Vehicle signal connector; 3507. Power connector; 3508. Vent valve; 3509. Third mounting hole; 3510. Hole limiting surface. Detailed Implementation

[0055] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the concept and technical solutions of the present invention, and to facilitate its implementation.

[0056] like Figures 1 to 26 As shown, the present invention provides an airtightness testing fixture for an integrated electric power steering system, including a connector sealing assembly for sealing all connectors and vent valves on the integrated unit, and an air intake positioning sealing assembly for mounting on the integrated unit and for supplying gas into the integrated unit during the test. The connector sealing assembly includes a vehicle sheath wiring harness 1 and a power sheath wiring harness 2. The vehicle sheath wiring harness 1 and the power sheath wiring harness 2 are configured to connect the programming device and the connectors on the integrated unit when programming the integrated unit is performed during the test.

[0057] Specifically, such as Figure 2 , Figure 5 and Figure 6 As shown, the connector sealing assembly includes a vehicle sheathed wiring harness 1, a power sheathed wiring harness 2, a first O-ring seal 3, a pressure sleeve 4, a sensor sheath 5, a sheath positioning block 601, a headless hexagonal screw 7, a locking nut 8, a first hexagonal nut 9, a second hexagonal nut 10, an adjusting screw 11, a third hexagonal nut 12, a fourth hexagonal nut 13, a fifth hexagonal nut 14, and a first quick-change clamp assembly 16. The first O-ring seal 3 is an O-ring seal.

[0058] The vehicle sheath wiring harness 1, power sheath wiring harness 2, and sensor sheath 5 are fixed in the sheath positioning block 601 with a small interference fit. A first O-ring seal 3, a pressure sleeve 4, and a headless hexagonal screw 7 are assembled in the lower hole of the sheath positioning block 601. The sheath positioning block 601, slider 1501, and first quick-change clamp assembly 16 are connected by threads using a locking nut 8, a first hexagonal nut 9, a second hexagonal nut 10, an adjusting screw 11, and a third hexagonal nut 12. Pressing the handle on the first quick-change clamp assembly 16 causes the vehicle sheath wiring harness 1, power sheath wiring harness 2, sensor sheath 5, and the first O-ring seal 3 on the pressure sleeve 4 on the sheath positioning block 601 to move down to the corresponding positions to form a seal and electrical connection with the vehicle signal connector 3506, power connector 3507, sensor signal connector 3505, and vent valve 3508 on the integrated unit 3501.

[0059] like Figure 2 , Figure 6 , Figure 21 , Figure 22 , Figure 26As shown, the pressure sleeve 4 is a stepped shaft-like part made of steel. Three stepped holes are provided in the middle of the large diameter of the lower end of the pressure sleeve 4. These three stepped holes are designated as the first, second, and third stepped holes, arranged sequentially along the axial direction of the pressure sleeve 4. The first stepped hole is located below the second stepped hole. The diameter of the first stepped hole is the same as the outer diameter of the first O-ring 3. The first O-ring 3 is adhered to the first stepped hole of the pressure sleeve 4 using sealing silicone. The first O-ring 3 is used to achieve a seal between the pressure sleeve 4 and the vent valve 3508. The depth of the first stepped hole of the pressure sleeve 4 is 0.4mm to 0.5mm less than the diameter of the first O-ring 3. This is to ensure sufficient O-ring compression to form a sealing surface between the first O-ring 3 and the housing bore surface of the vent valve 3508. The diameter of the second stepped hole is designed to avoid the boss surface at the mounting housing of the vent valve 3508. The third stepped hole is to avoid the exposed hexagonal head of the vent valve 3508. The upper small shaft diameter of the pressure sleeve 4 has an effective small clearance fit with the lower hole diameter of the sheath positioning block 601, and the top is provided with a notch for positioning and locking the headless hexagonal screw 7. The top center of the pressure sleeve 4 is provided with an internal threaded hole for screwing and fastening with the headless hexagonal screw 7.

[0060] like Figure 2 , Figure 5 , Figure 6 , Figures 11 to 13 , Figure 25 and Figure 26 As shown, the sheath positioning block 601 is made of steel, providing good strength. The upper end of the sheath positioning block 601 is respectively provided with vehicle sheath positioning holes 602, power sheath positioning holes 605, and sensor sheath positioning holes 603, which are the same in shape and smaller in size as the vehicle sheath wiring harness 1, power sheath wiring harness 2, and sensor sheath 5, and are interference-fitted. These are assembled and interference-fitted into the holes of the sheath positioning block 601. The lower left end face of the sheath positioning block 601 is provided with a countersunk hole for a small clearance fit with the upper shaft diameter of the pressure sleeve 4. The upper end of the countersunk hole axis is provided with an internal threaded hole for adjusting the axial position of the pressure sleeve 4 by screwing in a headless hexagonal screw 7. The upper end of the internal threaded hole coaxially provides a through hole for adjusting the axial position of the headless hexagonal screw 7 with a hexagonal wrench. The vehicle sheath positioning hole 602, power sheath positioning hole 605, sensor sheath positioning hole 603, and countersunk hole for positioning the pressure sleeve 4 are respectively connected to… Figure 25 and Figure 26The corresponding positions and dimensions of the vehicle signal connector 3506, power connector 3507, sensor signal connector 3505, and vent valve 3508 shown are consistent. By assembling the sheath positioning block 601 assembly, they can be smoothly assembled into position simultaneously. The upper end of the sheath positioning block 601 has a rectangular groove for installing the locking nut 8, and the upper end of the rectangular groove has a limiting hole 604 for assembling the adjusting screw 11. The locking nut 8, adjusting screw 11, first hexagonal nut 9, and second hexagonal nut 10 are used to position the sheath positioning block 601 assembly on the first quick-change clamp assembly 16, achieving a rapid clamping axial displacement method. The sealing of the vehicle signal connector 3506, power connector 3507, sensor signal connector 3505, and vent valve 3508 can be completed in one clamping operation.

[0061] The sheath positioning block 601 is connected to the first quick-change clamp assembly 16 via the adjusting screw 11. The axis of the adjusting screw 11 is parallel to the axis of the integrated machine. The adjusting screw 11 is fixed to the sheath positioning block 601 via the locking nut 8 and the first hexagonal nut 9. The adjusting screw 11 is fixed to the first quick-change clamp assembly 16 via the second hexagonal nut 10. The locking nut 8, the first hexagonal nut 9, and the second hexagonal nut 10 are threadedly connected to the adjusting screw, so that the distance between the sheath positioning block 601 and the first quick-change clamp assembly 16 is adjustable. The sheath positioning block 601 is located below the first quick-change clamp assembly 16. The first hexagonal nut 9 and the second hexagonal nut 10 are located between the sheath positioning block 601 and the first quick-change clamp assembly 16, with the first hexagonal nut 9 below the second hexagonal nut 10. The locking nut 8 is located below the first hexagonal nut 9. The sheath positioning block 601 has a limiting hole 604 for the adjusting screw 11 to pass through. The first hexagonal nut 9 is located above the limiting hole 604, and the locking nut 8 is located below the limiting hole 604. By tightening the locking nut 8, the first hexagonal nut 9, and the second hexagonal nut 10, the distance between the sheath positioning block 601 and the first quick-change clamp assembly 16 can be adjusted, thereby making the axial position of the sheath positioning block 601 adjustable.

[0062] like Figure 2 , Figure 5 , Figure 6 , Figures 14 to 15As shown, the airtightness testing fixture for the integrated electric steering system of the present invention also includes a slider 1501 connected to the connector sealing assembly and the air intake positioning sealing assembly. The axial position of the connector sealing assembly is adjustable. The slider 1501 is made of steel and has an L-shaped block structure. It is used to fix the first quick-change clamp assembly 16 and can withstand a large axial thrust. The right end of the slider 1501 is provided with a fillet R, and a through hole with a large clearance fit with the front external thread of the first quick-change clamp assembly 16 is provided at the concentric position of the fillet R. The slider 1501 is connected to the connector sealing assembly and the air intake positioning sealing assembly by two bolts, namely a second hexagon socket head cap screw 22 and a third hexagon socket head cap screw 23. The slider 1501 is provided with a first sliding waist-shaped groove 1502 and a second sliding waist-shaped groove 1503 for through mounting the second hexagon socket head cap screw 22 and the third hexagon socket head cap screw 23. The first sliding waist-shaped groove 1502 and the second sliding waist-shaped groove 1503 are waist-shaped grooves. The first sliding waist-shaped groove 1502 and the second sliding waist-shaped groove 1503 are the same length and are vertically arranged. The length of the first sliding waist-shaped groove 1502 and the second sliding waist-shaped groove 1503 is greater than the diameter of the second hexagon socket head cap screw 22 and the third hexagon socket head cap screw 23. The second hexagon socket head cap screw 22 passes through the first sliding waist-shaped groove 1502 and the third hexagon socket head cap screw 23 passes through the second sliding waist-shaped groove 1503. A fourth hexagonal nut 13 is provided on the first sliding slot 1502, and a fifth hexagonal nut 14 is provided on the second socket head cap screw 22. Rectangular protrusions are provided on the end faces of the two slots to prevent the fourth hexagonal nut 13 and the fifth hexagonal nut 14 from rotating and positioning. Tightening the second socket head cap screw 22, the third socket head cap screw 23, the fourth hexagonal nut 13, and the fifth hexagonal nut 14 can fix the slider 1501 together with the air intake positioning sealing assembly and the first quick-change clamp assembly 16. After loosening the second socket head cap screw 22, the third socket head cap screw 23, the fourth hexagonal nut 13, and the fifth hexagonal nut 14, the slider 1501 can be moved up and down. The slider 1501 drives the socket sealing assembly to move up and down synchronously, thereby realizing the adjustment of the axial position of the socket sealing assembly. The operation is convenient and simple.

[0063] like Figure 2 and Figure 5As shown, the intake positioning and sealing assembly includes a first hexagon socket bolt 17, a clamp positioning block 1801, a first positioning pin 19, a second quick-change clamp assembly 20, a second positioning pin 21, a second hexagon socket bolt 22, a third hexagon socket bolt 23, a sixth hexagon nut 24, an intake positioning sleeve 2501, a third positioning pin 26, a seventh hexagon nut 27, an intake pipe 28, an eighth hexagon nut 29, a locking sleeve 30, an air pipe connector 31, a fourth hexagon socket bolt 32, an intake pressure sleeve 33, and a second O-ring seal 34, wherein the second O-ring seal 34 is an O-ring seal. The second O-ring 34 is assembled in the first countersunk hole inside the intake sleeve 33. The clamp positioning block 1801, intake positioning sleeve 2501, intake sleeve 33, and second quick-change clamp assembly 20 are connected together by threaded fastening through the first hexagon socket bolt 17, the first locating pin 19, the second locating pin 21, the sixth hexagon nut 24, the third locating pin 26, the seventh hexagon nut 27, the eighth hexagon nut 29, the locking sleeve 30, and the fourth hexagon socket bolt 32. Pressing the handle on the second quick-change clamp assembly 20 causes the second O-ring 34 to move down and deform and compress against the stop sealing end face 3503 on the integrated machine 3501, forming an effective intake positioning and sealing method. The second quick-change clamp assembly 20 is used to control the vertical movement of the air intake sleeve 33. The air intake sleeve 33 is used to cooperate with the integrated machine to form an air intake sealing cavity. The second O-ring seal 34 is used to achieve a seal between the air intake sleeve 33 and the stop sealing end face 3503 of the integrated machine. An air intake pipe 28 is provided on the air intake sleeve 33. The air intake pipe 28 is connected to the air intake sealing cavity so that gas can enter the integrated machine.

[0064] like Figure 2 , Figure 5 , Figures 16 to 18As shown, the clamp positioning block 1801 is made of steel and is L-shaped. It is used to fix the second quick-change clamp assembly 20 and can withstand large axial thrust. The upper left end of the clamp positioning block 1801 has a rounded corner R, and a through hole with a large clearance fits with the front external thread of the second quick-change clamp assembly 20 is provided concentrically with the rounded corner R. The inner right side of the clamp positioning block 1801 has countersunk holes for installing the second and third hexagonal socket head cap screws 22 and 23. At the middle of the outer right side of the clamp positioning block 1801, a convex slider 1804 with a small clearance fits with the concave groove 1504 on the outer left side of the L-shaped slider 1501. This facilitates the vertical adjustment of the axial position of the connector sealing part and allows for length adjustment of the brushless motor with different axial dimensions, enabling rapid product changeover and saving on tooling manufacturing costs. The upper end face of the clamp positioning block 1801 is provided with a countersunk hole for fastening the first internal hex bolt 17 to the air intake positioning sleeve 2501. The lower end face of the clamp positioning block 1801 is provided with a first positioning hole 1802 and a second positioning hole 1803 for positioning and assembling the first positioning pin 19 and the second positioning pin 21 with a small clearance. The first positioning pin 19 is inserted into the first positioning hole 1802, and the second positioning pin 21 is inserted into the second positioning hole 1803.

[0065] like Figure 14 As shown, a concave sliding groove 1504 is provided in the middle of the two waist-shaped grooves on the outer side of the slider 1501, which is smaller in size and fits with the convex slider 1804 on the outer side of the right end of the clamp positioning block 1801. The first sliding waist-shaped groove 1502 and the second sliding waist-shaped groove 1503 are used to facilitate the up and down adjustment of the axial position of the connector sealing part, and can also realize the length adjustment of different axial dimensions of the brushless motor. The product can be changed quickly, and the tooling manufacturing cost is also saved.

[0066] like Figure 2 , Figure 5 , Figures 7 to 10 , Figure 25 , Figure 26As shown, the air intake positioning sleeve 2501 is used to install on the integrated machine 3501. The air intake positioning sleeve 2501 is a hollow component in the shape of a three-claw hook. The air intake positioning sleeve 2501 is made of steel, which has good mechanical strength. It is used to fix the upper end of the stop on the integrated machine 3501. The air intake positioning sleeve 2501 is provided with a first hook positioning surface 2502, a second hook positioning surface 2504, and a third hook positioning surface 2503 corresponding to the shape of the three-claw mounting surfaces of the first mounting hole 3502, the second mounting hole 3504, and the third mounting hole 3509 on the integrated machine 3501. The lower end of the air intake positioning sleeve 2501 is provided with a countersunk hole for a small clearance fit with the outer diameter of the air pressure sleeve 33 and the diameter of the stop on the integrated machine 3501, which facilitates assembly. The upper end of the countersunk hole of the air intake positioning sleeve 2501 is provided with a heart-shaped through hole to avoid the locking sleeve 30 and the air pipe connector 31 assembled on the air pressure sleeve 33. The intake pressure sleeve 33 is located within the countersunk hole of the intake positioning sleeve 2501. The intake pressure sleeve 33 can move and rotate axially relative to the intake positioning sleeve 2501. The intake pressure sleeve 33, the intake positioning sleeve 2501, and the integrated machine are coaxially arranged. The upper end face of the intake positioning sleeve 2501 is provided with a fourth positioning hole 2506 and a fifth positioning hole 2507 for positioning and assembling the first positioning pin 19 and the second positioning pin 21 with a small clearance. The intake positioning sleeve 2501 is located below the clamp positioning block 1801 and the two are fixedly connected. A threaded hole for engaging with the first hexagon socket bolt 17 for fastening the clamp positioning block 1801 is provided between the fourth positioning hole 2506 and the fifth positioning hole 2507 on the upper end face of the intake positioning sleeve 2501. The threaded hole passes through the countersunk hole at the lower end. The clamp positioning block 1801 is positioned and fixed on the upper end of the intake positioning sleeve 2501 by assembling the first positioning pin 19, the second positioning pin 21, and the first hexagon socket bolt 17. A third positioning hole 2505 for limiting the movement of the third positioning pin 26 is provided at the third hook positioning surface 2503 on the intake positioning sleeve 2501 with a small interference fit. The outer circular surface of the third positioning pin 26 contacts and limits the hole position on the integrated machine 3501 by contacting and limiting the position. This ensures that the positions and directions of the whole vehicle sheath wiring harness 1, power sheath wiring harness 2, sensor sheath 5, and pressure sleeve on the connector sealing assembly are accurately aligned with the four positions and directions of the whole vehicle signal connector 3506, power connector 3507, sensor signal connector 3505, and vent valve 3508 on the integrated machine 3501. The purpose is to facilitate rapid positioning and shorten the time required to complete a one-time clamping operation.

[0067] like Figure 2 , Figure 5 , Figure 19 , Figure 20As shown, the locking sleeve 30 is threadedly connected to the intake sleeve 33. The locking sleeve 30 is located above the intake sleeve 33. The locking sleeve 30 is connected to the second quick-change clamp assembly 20 above it via a fourth hexagon socket head cap screw 32. The fourth hexagon socket head cap screw 32 is threadedly connected to the eighth hexagon nut 29 and the seventh hexagon nut 27. The eighth hexagon nut 29 contacts the top surface of the locking sleeve 30. The locking sleeve 30 is an external hexagonal profile steel part. A through hole for assembling the first hexagon socket head cap screw 17 is provided in the middle of the upper end face. An internal threaded hole for engaging with the external thread of the upper end of the intake sleeve 33 is provided on the lower end face of the locking sleeve 30 along the same axis as the through hole. A rectangular thread relief groove is provided at the bottom of the internal threaded hole of the locking sleeve 30 to allow the internal thread of the locking sleeve 30 to engage with the external thread of the upper end of the intake sleeve 33.

[0068] like Figure 2 , Figure 5 , Figure 23 , Figure 24 As shown, the intake sleeve 33 is a convex-shaped shaft-like steel part with an external thread on its upper small diameter for engaging with the internal thread of the locking sleeve 30. A countersunk hole for accommodating the head of the fourth hexagon socket bolt 32 is provided on the upper end face of the intake sleeve 33, coaxial with the external thread. A tapered threaded hole for engaging with the air pipe connector 31 is provided on the left end face of the intake sleeve 33, improving the intake sealing effect. Two countersunk holes with different inner diameters are provided on the lower end of the intake sleeve 33, coaxial with the external thread; these are the first and second countersunk holes, with the first countersunk hole located below the second. The inner diameter of the first countersunk hole is slightly larger than that of the second. The diameter of the first countersunk hole is 0.5mm to 0.8mm smaller than the outer diameter of the second O-ring seal 34, creating a certain amount of compression to ensure that the O-ring seal 34 is assembled in the first countersunk hole and will not fall off during use. The depth of the first countersunk hole is 0.4mm to 0.5mm less than the wire diameter of the second O-ring 34. This is to ensure that the second O-ring 34 and the surface of the sealing end face 3503 on the integrated machine 3501 have sufficient O-ring compression to form an effective air intake sealing space. The second countersunk hole is to avoid the rotatable coupling located at the center of the upper end of the integrated machine 3501. The air intake pipe passes gas into the second countersunk hole. By using the fourth hexagon socket head cap screw 32, the locking sleeve 30, the seventh hexagon nut 27, the eighth hexagon nut 29, and the first hexagon socket head cap screw 17 to lock the air intake pressure sleeve 33, the air intake positioning sleeve 2501, and the clamp positioning block 1801 onto the second quick-change clamp assembly 20, a quick clamping axial displacement method is achieved, and the sealing of the air intake positioning sealing part can be completed in one clamping operation.

[0069] The programming device mainly consists of a computer and a power supply, with the corresponding programming software installed on the computer.

[0070] like Figures 1 to 6As shown, the connector sealing assembly and the intake positioning sealing assembly are connected by the second hexagonal bolt 22 and the third hexagonal bolt 23 on the locking clamp positioning block 1801 and the fourth hexagonal nut 13 and the fifth hexagonal nut 14 on the slider 1501, forming a function for simultaneous quick-change clamping and sealing of the connector sealing assembly and the intake positioning sealing assembly during assembly. Adding electrical wires for program burning to the vehicle sheath wiring harness 1 and the power sheath wiring harness 2 allows for simultaneous completion of product application program burning during the waiting time of the three airtightness testing processes: intake, pressure holding, and testing. This maximizes time utilization and improves production efficiency.

[0071] In this invention, the main change is to modify the operation method of disassembling and assembling bolts for the airtightness test of the integrated machine 3501. Instead, the first quick-change clamp assembly 16 connects to the sheath positioning block 601, facilitating the disassembly and assembly of various connectors and seals on the integrated machine 3501 and the vent valve. The second quick-change clamp assembly 20 connects to the intake pressure sleeve 33 in the intake positioning sleeve 2501, enabling the disassembly and assembly of intake positioning and sealing. The wires on the vehicle sheath wiring harness 1 and the power sheath wiring harness 2 connect the computer, the required power supply, and the vehicle signal connector 3506 and power connector 3507 on the integrated machine 3501, forming the program burning connection conditions. After pressing the airtightness test switch, the airtightness test is completed automatically. During this test time, the operator can perform product program burning. Simply press the start burning button on the computer program interface, and the computer will complete the program burning work on the integrated machine 3501 according to the set program.

[0072] This invention provides a method for airtightness testing of an integrated electric steering system, employing the aforementioned airtightness testing fixture for an integrated electric steering system, and comprising the following steps:

[0073] S1. Take the integrated testing and inspection machine;

[0074] S2. Air tightness testing fixture for integrated positioning electric steering system;

[0075] S3, Clamping of the connector and the air intake positioning seal;

[0076] S4. Conduct an airtightness test and program burning;

[0077] S5. Remove the integrated machine that has completed the airtightness test and program burning.

[0078] In step S1 above, first place the integrated machine 3501 with the stop end facing upwards on the testing worktable, such as... Figure 25 As shown.

[0079] In step S2 above, the operator holds the second quick-change clamp assembly 20 with their right hand, aligns the lower inner hole of the intake positioning sleeve 2501 with the center of the stop of the integrated machine 3501, places the third hook positioning surface 2503 of the upper end of the intake positioning sleeve 2501 to the left of the third mounting hole 3509 on the integrated machine 3501, rotates it counterclockwise, and then inserts the intake positioning sleeve 2501 downwards into the upper stop end face of the integrated machine 3501. The operator then rotates the second quick-change clamp assembly 20 held in their hand clockwise until the outer diameter of the third positioning pin 26 contacts and limits the hole on the integrated machine 3501. Figure 4 As shown.

[0080] In step S3 above, the operator holds the outer circle of the large end of the positioned air intake positioning sleeve 2501 with the left hand and holds the handle on the first quick-change clamp assembly 16 with the right hand and presses it down so that the vehicle sheath wiring harness 1, power sheath wiring harness 2, sensor sheath 5, and pressure sleeve 4 on the connector sealing part are respectively assembled into the four positions and directions of the vehicle signal connector 3506, power connector 3507, sensor signal connector 3505 and vent valve 3508 on the integrated machine 3501. The operator then grips the handle on the second quick-change clamp assembly 20 with their right hand and presses it downwards, causing the first hook positioning surface 2502, the second hook positioning surface 2504, and the third hook positioning surface 2503 on the intake positioning sleeve 2501 to contact the lower end faces of the first mounting holes 3502, the second mounting holes 3504, and the third mounting holes 3509 on the integrated machine 3501, respectively, forming three downward pulling forces. At this time, the second O-ring seal 34 on the intake pressure sleeve 33 and the surface of the stop sealing end face 3503 on the integrated machine 3501 form an effective intake sealing space, which is the press-fit in place. Figure 3 ,like Figure 5 As shown.

[0081] In step S4 above, the operator presses the airtightness test switch with their left hand. The equipment automatically closes the exhaust valve and opens the intake valve. The equipment begins to supply compressed air through the intake pipe 28 and the air pipe connector 31 into the intake pressure sleeve 33 for a set 10-second intake time. The compressed air then enters the integrated unit 3501 and is instantly filled to the set pressure requirement value, thus completing the intake process. Under the sealing effect of the second O-ring 34, the vehicle wiring harness 1, the power wiring harness 2, the sensor sleeve 5, and the pressure sleeve 4, an effective sealed space is formed inside the integrated unit 3501. This ensures that the compressed air entering the integrated unit 3501 is maintained at the set pressure requirement value. After this, the equipment automatically closes the intake valve and begins the pressure holding process for a set 10-second pressure holding time. After the pressure holding process is completed, the equipment automatically starts the 10-second pressure drop detection time. Once the pressure drop value is detected, the detection process is complete. The equipment automatically determines whether the pressure drop is acceptable based on the set requirements and issues a corresponding beep and "OK" or "NG" message. Then, the equipment automatically opens the exhaust valve, completing the airtightness test of the integrated unit 3501. The wires on the vehicle sheath harness 1 and power sheath harness 2 connect the computer, the required power supply, and the vehicle signal connector 3506 and power connector 3507 on the integrated unit 3501 to form the program burning connection conditions. After pressing the airtightness test switch, the airtightness test is completed automatically. During this test time, the operator can program the product by simply pressing the "Start Programming" button on the computer program interface. The computer will then complete the program burning process for the integrated unit 3501 according to the set program.

[0082] In step S5 above, the operator holds the outer circle of the large end of the positioned air intake positioning sleeve 2501 with his left hand, and holds the handle on the first quick-change clamp assembly 16 with his right hand and presses it upwards, so that the whole vehicle sheath wiring harness 1, power sheath wiring harness 2, sensor sheath 5, and pressure sleeve 4 on the connector sealing part are respectively disconnected from the whole vehicle signal connector 3506, power connector 3507, sensor signal connector 3505 and vent valve 3508 on the integrated machine 3501. The operator then uses their right hand to grasp the handle on the second quick-change clamp assembly 20 and presses it upwards, causing the second O-ring seal 34 on the intake sleeve 33 to disengage from the stop sealing end face 3503 on the integrated machine 3501. Releasing their left hand, the operator uses their right hand to grasp the second quick-change clamp assembly 20 and rotates it counterclockwise until the first hook positioning surface 2502, the second hook positioning surface 2504, and the third hook positioning surface 2503 on the intake positioning sleeve 2501 are respectively misaligned with the first mounting hole 3502, the second mounting hole 3504, and the third mounting hole 3509 on the integrated machine 3501, ensuring no contact. The operator then uses their right hand to lift the test fixture and remove the integrated machine 3501, which has been tested and programmed. At this point, the entire process of the airtightness test and programming of the integrated machine 3501 is complete.

[0083] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. An airtightness testing fixture for an integrated electric steering system, characterized in that, Includes a connector sealing assembly for sealing all connectors and vent valves on the integrated machine, and an intake positioning sealing assembly for mounting on the integrated machine and for supplying gas into the integrated machine during testing. The connector sealing assembly includes a vehicle sheathed wiring harness and a power sheathed wiring harness, which are configured to connect the programming device and the connectors on the integrated machine when programming the integrated machine is performed during testing. The connector sealing assembly also includes a sheath positioning block, a sensor sheath and a pressure sleeve disposed on the sheath positioning block, and a first quick-change clamp assembly for applying pressure to the sheath positioning block. The vehicle sheath wiring harness and the power sheath wiring harness are disposed on the sheath positioning block. The vehicle sheath wiring harness is connected to the vehicle signal connector of the integrated unit, and the power sheath wiring harness is connected to the power connector of the integrated unit. The pressure sleeve is configured to seal the vent valve. The sheath positioning block is provided with a vehicle sheath positioning hole, a power supply sheath positioning hole and a sensor sheath positioning hole. The vehicle sheath wiring harness is installed in the vehicle sheath positioning hole, the power supply sheath wiring harness is installed in the power supply positioning hole, and the sensor sheath is installed in the sensor sheath positioning hole. The sheath positioning block is connected to the push rod of the first quick-change clamp assembly via an adjusting screw. The adjusting screw is fixed to the sheath positioning block by a nut, and the nut and the adjusting screw are threaded together. The distance between the sheath positioning block and the first quick-change clamp assembly is adjustable.

2. The airtightness testing fixture for an integrated electric steering system according to claim 1, characterized in that, The air intake positioning and sealing assembly includes a clamp positioning block, a second quick-change clamp assembly disposed on the clamp positioning block, an air intake positioning sleeve connected to the clamp positioning block and used for mounting on the integrated machine, and an air intake pressure sleeve connected to the push rod of the second quick-change clamp assembly and used for cooperating with the integrated machine to form an air intake sealing cavity. An air intake pipe is disposed on the air intake pressure sleeve, and the air intake pipe communicates with the air intake sealing cavity.

3. The airtightness testing fixture for an integrated electric steering system according to claim 2, characterized in that, The air intake sleeve is provided with a first countersunk hole and a second countersunk hole. A sealing ring for contacting the integrated machine is provided in the first countersunk hole. The diameter of the first countersunk hole is smaller than the outer diameter of the sealing ring. The air intake pipe is connected to the second countersunk hole.

4. The airtightness testing fixture for an integrated electric steering system according to claim 2, characterized in that, The intake pressure sleeve is disposed in the central hole of the intake positioning sleeve, and the intake pressure sleeve moves axially relative to the intake positioning sleeve.

5. The airtightness testing fixture for an integrated electric steering system according to claim 2, characterized in that, The air intake positioning sleeve is provided with a first hook positioning surface, a second hook positioning surface, and a third hook positioning surface that correspond to the shape of the three-claw mounting surface of the first mounting hole, the second mounting hole, and the third mounting hole on the integrated machine. Positioning holes for inserting positioning pins are provided at the first hook positioning surface, the second hook positioning surface, or the third hook positioning surface. The positioning pins contact and limit the hole positioning surface on the integrated machine.

6. The airtightness testing fixture for an integrated electric steering system according to claim 2, characterized in that, It also includes a slider connected to the connector sealing assembly and the clamp positioning block, and the axial position of the connector sealing assembly is adjustable.

7. A test method for air tightness of an integrated electric power steering system, characterized in that, The airtightness test fixture for the integrated electric power steering system as described in any one of claims 1 to 6 is adopted, and includes the following steps: S1. Take the integrated testing and inspection machine; S2. Air tightness testing fixture for integrated positioning electric steering system; S3, Clamping of the connector and the air intake positioning seal; S4. Conduct an airtightness test and program burning; S5. Remove the integrated machine that has completed the airtightness test and program burning.

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