A transmission assembly break-in system and testing method

Abstract

This invention discloses a transmission assembly break-in system and testing method. The system includes a drive unit, a loading device, a break-in electronic control system, and a belt torque testing device. The drive unit includes an input motor and a connecting plate, which are coaxially connected to the input end of the transmission. The loading device is installed at the rear output end of the transmission. The belt torque testing device is located at the front output end of the transmission and includes a brake shaft, a brake, a torque meter I, a torque meter input shaft, and a flexible coupling, which are fixedly connected to the front output end of the transmission. The brake shaft and the brake are fixedly connected to the output end of the torque meter. The break-in electronic control system includes a four-wheel drive quick-switch device for testing the four-wheel drive switching of the transmission. This invention can quickly and accurately complete the factory testing and verification of the transmission, reducing the difficulty and cost of transmission testing and verification, and reducing the factory defect rate of the transmission.

Description

Technical Field

[0001] This invention relates to the field of testing technology for transmissions used in engineering machinery, and specifically to a transmission assembly break-in system and testing method. Background Technology

[0002] In the field of construction machinery, transmissions are installed on equipment such as backhoe loaders, telescopic forklifts, forklifts, scrapers, and wheeled excavators. To ensure a high pass rate before leaving the factory, transmissions manufactured for these construction machines typically undergo a break-in process to test their performance and reliability. However, most existing transmission break-in devices are general-purpose devices with few test items and lack specificity. Summary of the Invention

[0003] The purpose of this invention is to provide a transmission assembly break-in system and testing method to solve the problems existing in the prior art.

[0004] To achieve the above objectives, the present invention discloses a transmission assembly break-in system, comprising a drive unit, a break-in electronic control system, a loading device, and a belt torque testing device. The drive unit includes an input motor and a connecting plate, which are coaxially connected to the input end of the transmission in sequence. The loading device is connected to the rear output end of the transmission. The belt torque testing device is located at the front output end of the transmission and includes a brake shaft, a brake, a torque meter I, a torque meter input shaft, and a flexible coupling. The torque meter I, the torque meter input shaft, and the flexible coupling are connected in sequence, and the flexible coupling is fixedly connected to the front output end of the transmission. The brake shaft and the brake are fixedly connected to the output end of the torque meter I in sequence. The break-in electronic control system is electrically connected to the drive unit, the transmission, the loading device, and the belt torque testing device. The break-in electronic control system also includes a four-wheel drive / two-wheel drive quick switching device for performing a four-wheel drive / two-wheel drive switching test on the transmission.

[0005] As a further technical solution of the present invention, the loading device includes a loading motor, a motor base and a transmission shaft. The loading motor is fixedly connected to the transmission shaft, and the transmission shaft is fixedly connected to the rear output end of the transmission. The loading motor, the transmission shaft and the rear output end of the transmission have the same axis.

[0006] As a further technical solution of the present invention, the driving device includes an input motor and a connecting disk, wherein the input motor is coaxially connected to the connecting disk.

[0007] As a further technical solution of the present invention, torque meter II and torque meter III are respectively installed at the front output end and the rear output end of the transmission for detecting the torque at the output end.

[0008] As a further technical solution of the present invention, the input motor, the transmission, the loading device and the belt torque testing device are all fixedly installed on the base of the running-in table.

[0009] As a further technical solution of the present invention, the torque testing device further includes a brake mounting plate and a torque meter support. The brake mounting plate is fixedly connected to the brake, and the two ends of the torque meter support are fixedly connected to the torque meter and the running-in table base, respectively.

[0010] Secondly, the present invention also discloses a test method for a transmission, employing the transmission break-in system described above, the test method comprising two stages:

[0011] Phase 1 - Before Break-in Test

[0012] Step S1: Secure the input motor, connecting plate, and gearbox input end to the base of the running-in table in sequence and fix them coaxially. Then fix the loading motor, motor base, and drive shaft to the base. Adjust the position of the motor base so that the drive shaft is fixedly connected to the rear output end of the gearbox. Then fix the motor base to the base of the running-in table to complete the installation of the loading device.

[0013] Step S2: Connect the brake shaft, brake, brake mounting plate, torque meter I, torque meter input shaft, flexible coupling, and front output end of the transmission in a coaxial and fixed manner. Fix both ends of the torque meter support to the belt torque meter and the break-in table base to complete the installation of the belt torque testing device.

[0014] Step S3: Connect the break-in electronic control system (3) and complete the installation of the transmission break-in circuit and the four-wheel drive quick switching device (31);

[0015] Phase Two - Break-in Test

[0016] Step S4: The running-in table's electrical control system is powered on, the input motor is started, and the connecting plate and gearbox rotate coaxially.

[0017] Step S5: When the four-wheel drive quick switching device is not activated and the transmission is in four-wheel drive mode, both the front and rear output ends of the transmission have torque and speed output. The belt torque test device is not activated, but the loading device is activated. The torque is applied to the rear output end of the transmission through the loading motor and drive shaft to simulate the loading condition of the whole machine.

[0018] Step S6: When the four-wheel drive quick switching device is activated and the transmission is in two-wheel drive mode, there is torque and speed output at the rear output end of the transmission, but no torque and speed output at the front output end of the transmission. The loading device is activated to apply torque to the rear output end of the transmission to simulate the loading condition of the whole machine. If the front output end of the transmission is observed to rotate, the belt torque test device is activated to apply torque to the brake shaft through the brake and the magnitude of the belt torque of the transmission is detected by the torque meter I.

[0019] The beneficial effects of this invention are:

[0020] (1) The present invention is equipped with a four-wheel drive and two-wheel drive quick switching device, which can test and confirm the accuracy of the real-time switching of four-wheel drive and two-wheel drive. That is, the transmission has available four-wheel drive and two-wheel drive functions when it leaves the factory. This can prevent the driver from subjectively believing that it has four-wheel drive function, but when running, it does not execute four-wheel drive but only executes two-wheel drive mode, resulting in low traction force of the whole vehicle, reduced work efficiency and poor off-road ability.

[0021] (2) The present invention provides a belt pull test device. By performing belt pull test on the transmission, the transmission can be effectively protected. It can effectively prevent unnecessary wear of the front output or rear output related parts of the transmission, especially prevent excessive wear of the clutch friction plate and seal ring, so as to ensure the service life of the transmission.

[0022] (3) This transmission break-in device is modularly designed and can be used to conduct transmission break-in tests according to different test requirements. It can better simulate the actual working conditions of the transmission, which helps to reduce the failure rate of the transmission and improve the overall vehicle performance and user satisfaction. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the break-in system for the transmission assembly of the present invention;

[0024] Figure 2 This is a schematic diagram of the structure of the torque testing device.

[0025] Figure 3 This is a schematic diagram of a four-wheel drive quick-change device;

[0026] In the diagram, 1-Input motor; 2-Connecting disc; 3-Break-in bench electrical control system; 31-Four-wheel drive quick switching device; 4-Transmission; 5-Loading device; 51-Loading motor; 52-Motor base; 53-Drive shaft; 6-Break-in bench base; 7-Pulley torque testing device; 71-Brake shaft; 72-Brake; 73-Brake mounting plate; 74-Torque meter I; 75-Torque meter input shaft; 76-Flexible coupling; 77-Torque meter support; 8-Torque meter II; 9-Torque meter III. Detailed Implementation

[0027] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0028] like Figure 1 As shown, a transmission assembly break-in system includes a drive unit, a break-in electronic control system 3, a loading device 5, and a belt torque testing device 7. The drive unit includes an input motor 1 and a connecting plate 2, which are coaxially connected to the input end of the transmission 4. In this system, the input motor 1, the transmission 4, the loading device 5, and the belt torque testing device 7 are all fixedly mounted on the break-in bench base 6.

[0029] The loading device 5 is connected to the rear output end of the transmission 4. Specifically, the loading device 5 includes a loading motor 51, a motor base 52, and a drive shaft 53. The loading motor 51 is fixedly connected to the drive shaft 53, and the drive shaft 53 is fixedly connected to the rear output end of the transmission 4. The axes of the loading motor 51, the drive shaft 53, and the rear output end of the transmission 4 coincide.

[0030] like Figure 2 As shown, the belt torque testing device 7 is located at the front output end of the transmission 4 and includes a brake shaft 71, a brake 72, a brake mounting plate 73, a torque meter 74, a torque meter input shaft 75, a flexible coupling 76, and a torque meter support 77. The torque meter 74, torque meter input shaft 75, and flexible coupling 76 are sequentially and fixedly connected to the front output end of the transmission 4 to transmit the transmission output torque signal to the torque meter 74. The brake mounting plate 73 is fixedly connected to the brake 72 to fix the brake position. The brake shaft 71, brake 72, and brake mounting plate 73 are sequentially and fixedly connected to the output end of the torque meter 74 to apply a braking torque signal to the torque meter. The brake shaft 71 and brake 72 are sequentially and fixedly connected to the output end of the torque meter 74. The torque meter 74 calculates the output torque of the transmission belt by combining the input torque and the applied braking torque signal at the output end. The torque meter support 77 is fixedly connected at both ends to the torque meter I74 and the running table base 6, respectively, to fix the position of the torque meter.

[0031] During the mass production of transmissions, due to unavoidable differences in the cumulative tolerances of many components, some transmissions may exhibit a "coupling" phenomenon. This means that when the transmission is shifted to neutral, the front or rear output clutches remain engaged and continue to transmit torque. If a transmission with this coupling phenomenon is assembled into a complete vehicle, the vehicle will experience a malfunction where it runs in neutral.

[0032] After the belt pull test of this system, the safety hazard of the whole machine running in neutral due to belt pull torque was eliminated, excessive wear of the friction plates and seals of the front and rear output clutches was avoided, as well as other related parts damaged by the high temperature of the belt pull, thus extending the service life of the transmission, reducing the company's quality losses and improving safety.

[0033] The break-in electronic control system 3 is electrically connected to the drive unit, transmission 4, loading device 5, and belt drive test device 7. The break-in electronic control system 3 also includes a four-wheel drive / two-wheel drive quick switching device 31, used to perform four-wheel drive / two-wheel drive switching tests on the transmission 4.

[0034] like Figure 3 As shown, the four-wheel drive quick-change device 31 includes a control panel, which has displays for torque values ​​from torque meters I8 and II9, as well as a four-wheel drive switching button. Torque meters I8 and II9 are respectively installed at the front and rear output ends of the transmission 4.

[0035] Four-wheel drive is generally used in the transmissions of construction machinery, such as backhoe loaders (commonly known as double-headers), some telescopic boom forklifts, medium and large tonnage hydraulic mechanical transmission forklifts, small and medium-sized underground shovels and coal miners, and some models of wheeled excavators. The four-wheel drive system allows the machine to switch between four-wheel and two-wheel drive in real time according to different working conditions, road surface speed requirements, and other specific needs, thus meeting the machine's various loading and unloading operations and relocation requirements.

[0036] If the transmission's four-wheel drive / two-wheel drive switching function is not tested and confirmed at the factory, the vehicle will switch to the default four-wheel drive mode when the driver needs to perform low-speed traction or loading operations with high driving force. However, if the transmission's low-speed four-wheel drive mode is not tested and confirmed at the factory, the transmission may only have a two-wheel drive mode due to factors such as oil circuit blockage, solenoid valve jamming, abnormal voltage in the electronic control system, or other unidentified faults. In this case, directly operating the vehicle will cause the low-speed four-wheel drive mode to be incorrectly used as a two-wheel drive mode. This will result in low overall vehicle traction, reduced work efficiency, and poor off-road capability on soft, swampy, or muddy roads. Under heavy load conditions, prolonged operation may cause the transmission's two-wheel drive clutches to slip and fail, accompanied by high temperatures in the equipment, significantly reducing the transmission's lifespan and increasing its failure rate.

[0037] Similarly, when drivers need to perform long-distance high-speed unloaded driving or fully loaded transfer transportation, the vehicle may mistakenly use four-wheel drive mode instead of two-wheel drive mode (the driver is unaware of the vehicle's actual operating mode). This will result in the vehicle's maximum speed being lower than expected, and the excess traction will cause the vehicle to sway and wobble at high speeds, significantly reducing the safety of the vehicle and its occupants. At the same time, the excess traction will cause parasitic power between equipment, leading to rapid wear on transmission components such as the gearbox, increasing unnecessary fuel consumption, and reducing the service life of transmission components such as the gearbox. Figure 3The diagram shows the working principle of the four-wheel drive quick switching device. Taking the initial state as four-wheel drive and the switch to two-wheel drive rear-wheel drive as an example, there is a four-wheel drive switching button on the display screen of the break-in bench control panel. It is connected to the four-wheel drive solenoid valve of the transmission through the circuit. The four-wheel drive solenoid valve controls the engagement and disengagement of the four-wheel drive clutch of the transmission by controlling the opening and closing of the oil circuit, thereby realizing the four-wheel drive switching of the whole machine.

[0038] If the four-wheel drive switching function of the transmission is normal, the theoretical result is: when the four-wheel drive switching button on the break-in platform control panel is not pressed or clicked, the transmission outputs in four-wheel drive, and the break-in platform control panel displays torque values ​​for both the front and rear outputs of the transmission; when the four-wheel drive switching button on the break-in platform control panel is pressed or clicked, the transmission switches to two-wheel drive output, and the break-in platform control panel displays torque values ​​for the rear output of the transmission, while the front output has no torque value or the torque value is approximately 0.

[0039] If the break-in phenomenon does not match the theoretical results, it proves that the four-wheel drive switching function of the transmission is abnormal.

[0040] In addition, if the transmission can switch between four-wheel drive and two-wheel drive in real time according to vehicle speed, different speed values ​​can be set for four-wheel drive and two-wheel drive to break in the vehicle. The real-time switching function between four-wheel drive and two-wheel drive can be confirmed by the front and rear output torque of the transmission.

[0041] In this break-in system, the four-wheel drive quick switching device 31, the loading device 5, and the belt torque testing device 7 are all modular designs, which can simultaneously test the break-in status of the transmission, or can be used separately according to the actual needs of the transmission.

[0042] This invention also discloses a test method for a transmission, comprising:

[0043] Phase 1 - Before Break-in Test

[0044] Step S1: Securely connect the input motor 1, connecting plate 2, and input end of the gearbox 4 coaxially in sequence, and fix them on the break-in table base 6; then fix the loading motor 51, motor base 52, and drive shaft 53 in place, adjust the position of the motor base 52 so that the drive shaft 53 is fixedly connected to the rear output end of the gearbox 4, and then fix the motor base 52 on the break-in table base 6 to complete the installation of the loading device 5;

[0045] Step S2: Connect the brake shaft 71, brake 72, brake mounting plate 73, torque meter I74, torque meter input shaft 75, flexible coupling 76, and front output end of transmission 4 in a coaxial and fixed manner. Fix both ends of torque meter support 77 to torque meter I74 and break-in table base 6 to complete the installation of the belt torque test device 7.

[0046] Step S3: Connect the break-in electronic control system and complete the installation of the transmission break-in circuit and the four-wheel drive quick switching device 31;

[0047] Phase Two - Break-in Test

[0048] Step S4: The running-in table electrical control system 3 is powered on, the input motor 1 is started, and the connecting plate 2 and the gearbox 4 rotate coaxially.

[0049] Step S5: When the four-wheel drive quick switching device 31 is not activated and the transmission 4 is in four-wheel drive mode, both the front and rear output ends of the transmission 4 have torque and speed output. The belt torque test device 7 is not activated, but the loading device 5 is activated. The loading motor 51 and the drive shaft 53 apply torque to the rear output end of the transmission 4 to simulate the loading condition of the whole machine.

[0050] Step S6: When the four-wheel drive quick switching device 31 is activated and the transmission 4 is in two-wheel drive mode, the rear output end of the transmission 4 has torque and speed output, while the front output end of the transmission 4 has no torque and speed output; the loading device 5 is activated to apply torque to the rear output end of the transmission 4 to simulate the loading condition of the whole machine; if the front output end of the transmission 4 is observed to rotate, the belt torque test device 7 is activated, and the torque is applied to the brake shaft 71 through the brake 72, and the magnitude of the belt torque of the transmission 4 is detected by the torque meter I74.

[0051] In summary, this transmission break-in assembly system and testing method, through the synergistic effect of the loading device, belt and exhaust testing device, and four-wheel drive real-time switching device, reduces the difficulty and verification cost of transmission testing, improves testing efficiency, can better simulate the actual working conditions of the transmission, helps reduce the transmission factory defect rate, and improves overall vehicle performance and user satisfaction.

[0052] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes that can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention are all within the protection scope of the claims of the present invention.

Claims

1. A method of testing a transmission, characterized by, A transmission assembly break-in system is adopted, the system including a drive unit, a break-in electronic control system (3), a loading device (5), and a belt torque testing device (7). The drive unit includes an input motor (1) and a connecting plate (2). The input motor (1) and the connecting plate (2) are coaxially connected to the input end of the transmission (4) in sequence. The loading device (5) is connected to the rear output end of the transmission (4). The belt torque testing device (7) is located at the front output end of the transmission (4) and includes a brake shaft (71), a brake (72), a torque meter I (74), a torque meter input shaft (75), and a flexible coupling (76). The torque meter I (74), the torque meter input shaft (75), and the flexible coupling (76) are connected in sequence, and the flexible coupling (76) is fixedly connected to the front output end of the transmission (4); the brake shaft (71) and the brake (72) are fixedly connected to the output end of the torque meter I (74) in sequence; the break-in electronic control system (3) is electrically connected to the drive device, the transmission (4), the loading device (5), and the belt torque testing device (7) respectively; the break-in electronic control system (3) also includes a four-wheel drive and two-wheel drive quick switching device (31) for performing a four-wheel drive and two-wheel drive switching test on the transmission (4); The loading device (5) includes a loading motor (51), a motor base (52) and a transmission shaft (53). The loading motor (51) is fixedly connected to the transmission shaft (53), and the transmission shaft (53) is fixedly connected to the rear output end of the gearbox (4). The loading motor (51), the transmission shaft (53) and the rear output end of the gearbox (4) have the same axis. The testing methods include a break-in testing phase, as detailed below: When the break-in electronic control system (3) is powered on, the input motor (1) starts, driving the connecting plate (2) and the transmission (4) to rotate coaxially; when the four-wheel drive quick switching device (31) is not started, and the transmission (4) is in four-wheel drive mode, both the front and rear output ends of the transmission (4) have torque and speed output, the belt torque test device (7) is not started, the loading device (5) starts, and the torque is applied to the rear output end of the transmission (4) through the loading motor (51) and the drive shaft (53) to simulate the loading condition of the whole machine; when the four-wheel drive quick switching device (31) is powered on, the input motor (1) starts, driving the connecting plate (2) and the transmission (4) to rotate coaxially; when the four-wheel drive quick switching device (31) is not started, the transmission (4) is in four-wheel drive mode, the transmission (4) has torque and speed output ... When the gearbox (4) is in two-wheel drive mode, the rear output end of the gearbox (4) has torque and speed output, while the front output end of the gearbox (4) has no torque and speed output. The loading device (5) is started to apply torque to the rear output end of the gearbox (4) to simulate the loading condition of the whole machine. If the front output end of the gearbox (4) is observed to rotate, the belt torque test device (7) is started to apply torque to the brake shaft (71) through the brake (72), and the magnitude of the belt torque of the gearbox (4) is detected by the torque meter I (74).

2. The test method of claim 1, wherein, The testing method includes a pre-break-in test phase, as detailed below: The input motor (1), connecting plate (2), and gearbox (4) are sequentially and coaxially connected and fixedly installed on the break-in table base (6); then the loading motor (51), motor base (52), and drive shaft (53) are fixedly connected, the position of the motor base (52) is adjusted so that the drive shaft (53) is fixedly connected to the rear output end of the gearbox (4), and then the motor base (52) is fixed on the break-in table base (6) to complete the installation of the loading device (5); The brake shaft (71), brake (72), brake mounting plate (73), torque meter I (74), torque meter input shaft (75), flexible coupling (76), and front output end of transmission (4) are sequentially and fixedly connected coaxially. The two ends of the torque meter support (77) are fixed on the torque meter I (74) and the running-in table base (6) to complete the installation of the belt torque test device (7). Connect the break-in electronic control system (3) and complete the installation of the transmission break-in circuit and the four-wheel drive quick switching device (31).

3. The test method of claim 2, wherein, The driving device includes an input motor (1) and a connecting plate (2), wherein the input motor (1) and the connecting plate (2) are coaxially connected.

4. The test method according to claim 3, characterized in that, Torque meter II (8) and torque meter III (9) are installed at the front and rear output ends of the transmission (4) respectively to detect the torque at the output end.

5. The test method according to claim 4, characterized in that, The input motor (1), the gearbox (4), the loading device (5), and the belt torque testing device (7) are all fixedly installed on the break-in table base (6).

6. The test method according to claim 5, characterized in that, The torque testing device (7) further includes a brake mounting plate (73) and a torque meter support (77). The brake mounting plate (73) is fixedly connected to the brake (72), and the two ends of the torque meter support (77) are fixedly connected to the torque meter I (74) and the running-in table base (6), respectively.

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