Drive axle assembly thrust rod support test bench and test method

Abstract

The invention relates to a drive axle assembly thrust rod support test bed, which comprises a shaft tube clamp, a thrust rod support, a counter-force seat, an oil cylinder hanging bracket, a hydraulic oil cylinder and a control system, and is characterized in that the thrust rod support comprises an upper thrust rod support and a lower thrust rod support, and the upper thrust rod support and the lower thrust rod support are respectively welded on an axle housing assembly. Two ends of an axle housing assembly to be tested are respectively arranged on the axle tube clamps, the hydraulic oil cylinder is arranged on the oil cylinder hanging bracket, a sensor is arranged on the hydraulic oil cylinder, and one end of the hydraulic oil cylinder is connected with the counter-force seat. One end of the hydraulic oil cylinder is connected with one thrust rod bracket, the other thrust rod brackets are respectively connected with the corresponding counter-force seats, the hydraulic oil cylinder and the sensor are respectively connected with the control system, and a loading force test is carried out on the thrust rod brackets through the hydraulic oil cylinder; the test frequency is 0.5-2 Hz, and the conditions of no welding seam, axle housing cracking, bracket deformation and the like after the loading test is carried out for 200 thousand times are considered to be qualified.

Description

Technical Field

[0001] The invention relates to a bracket test bench, in particular to a driving axle assembly thrust rod bracket test bench and a test method. Background Art

[0002] The upper and lower thrust rod brackets of the automobile drive axle are very important accessories of the axle assembly. They are connected to the frame through the thrust rods, and transmit the driving force of the engine and the braking force generated by the friction between the tires and the ground to the frame, so that the vehicle can drive safely and smoothly. In addition, it is also subject to the centrifugal force and impact force generated when the car turns or passes through potholes. If the bracket is not strong enough or there is a problem with the welding process, it will cause the bridge shell to crack and leak oil, causing wear of the drive axle; in severe cases, the thrust rod bracket will break, resulting in a safety accident of vehicle loss of control. However, such an important and critical accessory does not have a corresponding test bench, test standard or method. Summary of the invention

[0003] The technical problem to be solved by the present invention is: based on the deficiencies of the prior art, an effective test bench and test method are provided to verify the inherent strength of the upper and lower thrust rod brackets of an automobile drive axle and the strength fatigue life after being welded to the drive axle housing.

[0004] The technical solution to solve the above technical problems is: a test bench for a thrust rod bracket of a drive axle assembly, including an axle tube clamp, a thrust rod bracket, a reaction seat, a cylinder hanger, a hydraulic cylinder and a control system, the thrust rod bracket including an upper thrust rod bracket and a lower thrust rod bracket, the upper thrust rod bracket and the lower thrust rod bracket are respectively welded to the bridge housing assembly, when in use, the two ends of the bridge housing assembly to be tested are respectively arranged on the axle tube clamp, the hydraulic cylinder is arranged on the cylinder hanger, a sensor is provided on the hydraulic cylinder, one end of the hydraulic cylinder is connected to the reaction seat; one end of the hydraulic cylinder is connected to a thrust rod bracket, and the other thrust rod brackets are respectively connected to the corresponding reaction seats, the hydraulic cylinder and the sensor are respectively connected to the control system, and the thrust rod bracket is subjected to a loading force test through the hydraulic cylinder; the test frequency is 0.5~2Hz, and after 200,000 loading tests, if there is no weld, bridge housing cracking and bracket deformation, it is considered qualified.

[0005] A further technical solution of the present invention is: when testing the upper thrust rod bracket, the other end of the hydraulic cylinder is connected to the upper thrust rod bracket, and the two lower thrust rod brackets are respectively connected to the corresponding reaction seats; when testing the lower thrust rod bracket, the other end of the hydraulic cylinder is connected to any one of the two lower thrust rod brackets, and the remaining lower thrust rod bracket and the upper thrust rod bracket are respectively connected to the corresponding reaction seats.

[0006] A displacement sensor is installed in the hydraulic cylinder, and a force sensor is installed at the loading end of the servo hydraulic oil. The test loading force value is controlled by the control system, and force protection and displacement protection are set on the control system according to the test loading force value and deformation.

[0007] A connecting plate and a thrust rod fixing bracket are arranged on the reaction seat, the thrust rod fixing bracket is arranged on the reaction seat through the connecting plate, strip-shaped bolt holes are opened on the mounting plate of the reaction seat, and bolt holes are arranged on the connecting plate.

[0008] The axle tube clamp includes an upper axle tube seat, a lower axle tube seat, an axle tube seat connecting plate, a sliding module and a support plate. The upper axle tube seat is fixedly connected to the lower axle tube seat to form a clamp for clamping the two ends of the bridge housing assembly. The lower axle tube seat is arranged on the axle tube seat connecting plate, and an arc groove is arranged on the axle tube seat connecting plate. The axle tube seat connecting plate is arranged on the sliding module, and the sliding module is arranged on the support plate. The support plate is provided with limit blocks at both ends of the sliding module, and the limit blocks are used to move the sliding module forward and backward.

[0009] The sliding module includes a rolling skateboard and a skateboard seat. The rolling skateboard is provided with a semicircular shaft corresponding to the arc groove. The shaft tube seat connecting plate is arranged on the rolling skateboard. The arc groove of the shaft tube seat connecting plate is correspondingly placed on the semicircular shaft of the rolling skateboard. The shaft tube seat connecting plate can rotate back and forth repeatedly around the rolling skateboard. The rolling skateboard is placed on the skateboard seat. The skateboard seat is located between the limit blocks. The limit blocks are located at the front and rear ends of the skateboard seat. The limit blocks are used to move the sliding module forward and backward. The rolling skateboard can move left and right along the skateboard seat. The skateboard seat is fixedly arranged on the support plate.

[0010] The sliding module includes a roller support plate and a roller. The roller support plate is provided with an arc-shaped roller groove, and the roller is placed in the roller groove. The arc-shaped groove of the shaft tube seat connecting plate is correspondingly placed on the roller. The shaft tube seat connecting plate can rotate back and forth around the roller, and the roller support plate is fixedly arranged on the support plate.

[0011] The axle tube fixture also includes an axle tube clamp, and the two ends of the bridge housing assembly are clamped between the upper axle tube seat and the lower axle tube seat by the axle tube clamp.

[0012] Due to the adoption of the above technical solution, a drive axle assembly thrust rod bracket test bench and test method of the present invention have the following beneficial effects: The present invention provides an effective test bench and test method for verifying the strength of the upper and lower thrust rod brackets of the automobile drive axle and the strength fatigue life after being welded to the drive axle housing. It ensures that the produced and welded products are strictly tested before being delivered to customers, and also ensures whether the production process and welding process of the thrust rod bracket meet the product consistency requirements. At the same time, establishing a set of effective test methods and test benches can not only speed up the product development cycle and effectively verify product quality, but also prevent uninspected products from being put on the market and endangering driving safety.

[0013] The present invention simplifies the loading and fixing methods of the test bench according to the automobile suspension structure, eliminates the complicated automobile suspension system and multiple accessories, makes the test bench easy to assemble, and improves the test efficiency. The upper thrust rod bracket and the lower thrust rod bracket test can be completed through assembly adjustment. The test bench has strong versatility and ensures the effectiveness and traceability of the test.

[0014] Next, the technical features of a drive axle assembly thrust rod bracket test bench and a test method of the present invention are further described in conjunction with the accompanying drawings and specific embodiments of the specification. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 : Schematic diagram of the structure of a drive axle assembly thrust rod bracket test bench.

[0016] Figure 2 : Schematic diagram of the installation status of the servo hydraulic cylinder.

[0017] Figure 3 : Schematic diagram of the reaction seat structure.

[0018] Figure 4 : Schematic diagram of the shaft tube clamp structure.

[0019] Figure 5 : Schematic diagram of the test state when the servo hydraulic cylinder is connected to the upper thrust rod bracket.

[0020] Figure 6 : Schematic diagram of the test state when the servo hydraulic cylinder is connected to one of the lower thrust rod brackets.

[0021] In the above drawings, the descriptions of the reference numerals are as follows: 1-axle tube fixture, 2-bridge housing assembly, 3-upper thrust rod bracket, 4-lower thrust rod bracket, 5-fixed seat, 6-reaction seat, 7-connecting plate, 8-servo hydraulic cylinder, 9-cylinder hanger, 10-force sensor, 11-loading bracket, 12-thrust rod fixing bracket, 101-support plate, 102-upper axle tube seat, 103-axle tube clamp, 104-lower axle tube seat, 105-axle tube seat connecting plate, 106-rolling slide plate, 107-slide plate seat, 108-limiting plate, 109-roller, 110-roller support plate. DETAILED DESCRIPTION

[0022] A test bench for a driving axle assembly thrust rod bracket comprises an axle tube clamp, a thrust rod bracket, a reaction seat, a cylinder hanger, a hydraulic cylinder and a control system, wherein the thrust rod bracket comprises an upper thrust rod bracket and a lower thrust rod bracket, the upper thrust rod bracket and the lower thrust rod bracket are respectively welded to the axle housing assembly, the upper thrust rod bracket is welded to the middle of the axle housing assembly, and two lower thrust rod brackets are respectively welded to the two ends of the axle housing assembly. When in use, the two ends of the axle housing assembly to be tested are respectively arranged on the axle tube clamp, the hydraulic cylinder is arranged on the cylinder hanger, a sensor is arranged on the hydraulic cylinder, one end of the hydraulic cylinder is connected to the reaction seat; one end of the hydraulic cylinder is connected to a thrust rod bracket, and the other thrust rod brackets are respectively connected to the corresponding reaction seats, the hydraulic cylinder and the sensor are respectively connected to the control system, and a loading force test is performed on the thrust rod bracket through the hydraulic cylinder; the test frequency is 0.5~2Hz, and it is considered qualified if no weld, axle housing cracking and bracket deformation occur after 200,000 times of loading test. When testing the upper thrust rod bracket, the other end of the hydraulic cylinder is connected to the upper thrust rod bracket, and the two lower thrust rod brackets are respectively connected to the corresponding reaction seats; when testing the lower thrust rod bracket, the other end of the hydraulic cylinder is connected to any one of the two lower thrust rod brackets, and the remaining lower thrust rod bracket and the upper thrust rod bracket are respectively connected to the corresponding reaction seats.

[0023] The shaft tube clamp includes an upper shaft tube seat, a lower shaft tube seat, a shaft tube seat connecting plate, a sliding module and a support plate. The upper shaft tube seat is fixedly connected with the lower shaft tube seat to form a clamp for clamping the two ends of the bridge housing assembly. The lower shaft tube seat is arranged on the shaft tube seat connecting plate, and the shaft tube seat connecting plate is provided with an arc groove. The shaft tube seat connecting plate is arranged on the sliding module, and the sliding module is arranged on the support plate. The support plate is provided with limit blocks at both ends of the sliding module, and the limit blocks are used to move the sliding module forward and backward. The support plate is fixedly arranged on the fixed seat, and the sliding module includes a first sliding module and a second sliding module. The sliding module (first sliding module) includes a rolling slide and a slide seat. The rolling slide is provided with a semicircular shaft corresponding to the arc groove. The shaft tube seat connecting plate is arranged on the rolling slide. The arc groove of the shaft tube seat connecting plate is placed on the semicircular shaft of the rolling slide. The shaft tube seat connecting plate can rotate back and forth around the rolling slide. The rolling slide is placed on the slide seat. The slide seat is located between the limit blocks. The limit blocks are located at the front and rear ends of the slide seat. The limit blocks are used to move the sliding module forward and backward. The rolling slide can move left and right along the slide seat. The slide seat is fixedly arranged on the support plate. The sliding module (second sliding module) includes a roller support plate and a roller. The roller support plate is provided with an arc-shaped roller groove. The roller is placed in the roller groove. The arc groove of the shaft tube seat connecting plate is placed on the roller. The shaft tube seat connecting plate can rotate back and forth around the roller. The roller support plate is fixedly arranged on the support plate. According to needs, when using and installing, the two sliding modules can have the same structure or different structures. The axle tube fixture also includes an axle tube clamp, and the two ends of the bridge housing assembly are clamped between the upper axle tube seat and the lower axle tube seat by the axle tube clamp. Different sizes of axle tube clamps can be replaced according to different sizes of bridge housing assemblies to facilitate clamping of bridge housing assemblies of different sizes. For ease of use, grease can be provided on the slide seat, and the rolling slide and the slide seat are lubricated by grease.

[0024] A displacement sensor is provided in the hydraulic cylinder, and a force sensor is installed at the loading end of the servo hydraulic oil. The test loading force value is controlled by the control system, and force value protection and displacement protection are set on the control system according to the test loading force value and deformation. A connecting plate and a thrust rod fixing bracket are provided on the reaction seat. The thrust rod fixing bracket is set on the reaction seat through the connecting plate. The mounting plate of the reaction seat is provided with strip-shaped bolt holes, and the connecting plate is provided with bolt holes. The thrust rod fixing bracket is fixed to the connecting plate by bolts. The connecting plate is positioned on the mounting plate of the reaction seat by bolts. By tightening the bolts, the connecting plate can be positioned at the required height, thereby facilitating adjustment. When in use, one end of the hydraulic cylinder and the thrust rod bracket are fixedly connected to the corresponding thrust rod fixing bracket by bolts respectively. The other end of the hydraulic cylinder is connected to the thrust rod bracket through the loading bracket.

[0025] Specifically, a driving axle assembly thrust rod bracket test bench includes an axle tube clamp, a thrust rod bracket, a reaction seat, a cylinder hanger and a servo hydraulic cylinder, and the thrust rod bracket is welded to the bridge housing assembly. The two ends of the bridge housing assembly 2 are clamped by the axle tube clamp 1, and the axle tube clamp 1 is fixed on the fixed seat 5. The servo hydraulic cylinder and the mounting device are arranged on the cylinder hanger 9, and the tail end of the servo hydraulic cylinder 8 is connected and fixed to the reaction seat 6 through the connecting plate 7. The front end of the servo hydraulic cylinder 8 is mounted on the cylinder hanger 9, and the servo hydraulic cylinder 8 can adjust the upper and lower installation heights of the reaction seat 6 and the cylinder hanger 9 according to the test assembly loading height. The front end of the servo hydraulic cylinder 8 is connected to a force sensor 10 and a loading bracket 11, and the loading bracket 11 is connected to one of the thrust rod brackets, and the other two thrust rod brackets are connected to the thrust rod fixed bracket 12, and the thrust rod fixed bracket 12 is connected and fixed to the reaction seat 6 through the connecting plate 7. The thrust rod fixing bracket 12 can be installed at a height on the reaction seat 6 through the connecting plate 7 according to the bracket height.

[0026] When testing the thrust rod bracket on the drive axle assembly, the servo hydraulic cylinder and the mounting device are hung on the cylinder hanger through the hanger rod, one end of the servo hydraulic cylinder is connected and fixed to a reaction seat through a connecting plate, the other end of the servo hydraulic cylinder is horizontally connected to one end 11 of the loading bracket, and the other end of the loading bracket 11 is horizontally connected to the upper thrust rod bracket 3 on the bridge housing assembly, and the lower thrust rod brackets 4 at both ends of the bridge housing assembly are respectively connected and fixed to the corresponding reaction seats through thrust rod fixing brackets 12.

[0027] When testing the lower thrust rod bracket of the drive axle assembly, the servo hydraulic cylinder and the mounting device are hung on the cylinder hanger through the hanging rod, and the upper push rod bracket on the axle housing assembly is connected and fixed to the corresponding reaction seat through the thrust rod fixing bracket 12. One end of the servo hydraulic cylinder is connected and fixed to a reaction seat through a connecting plate, and the other end of the servo hydraulic cylinder is horizontally connected to one end of the loading bracket 11, and the other end of the loading bracket 11 is horizontally connected to any lower thrust rod bracket on the axle housing assembly, and the other lower thrust rod bracket is connected and fixed to the corresponding reaction seat through the thrust rod fixing bracket 12.

[0028] The test bench uses a servo hydraulic cylinder as a loading device. The servo hydraulic cylinder has a built-in displacement sensor. The loading end of the servo hydraulic cylinder is equipped with a force sensor. The servo hydraulic cylinder and the sensor are connected to the control system respectively. The test loading force value is controlled by the control system, and the force deformation of the bracket when the test load is loaded can be checked. The control system can set force protection and displacement protection according to the test loading force value and deformation. The control system can set the test force value for protection, which can effectively avoid misoperation and damage to the test piece due to excessive test force. The control system can set the extension and contraction of the action cylinder for protection. Under the specified test force, the deformation of the test sample reaches balance and remains within a certain range. Only when the test piece fails or the fastener is loose or broken, the balance changes, and the test bench system automatically alarms and stops the test, without the need for the tester to pay attention to and record the test situation all the time. The number of tests can be set by the control system, and the number of tests can be set according to the test cycle requirements. When the number of tests is reached, the test stops.

[0029] By replacing the axle tube fixture, the axle tube test of different axle housing sizes can be met. During assembly, the angle of the axle housing assembly set on the axle tube fixture can be adjusted according to the force angle of the thrust rod, so that the elevation angle of the axle housing assembly can be adjusted to make it consistent with the designed force state of the vehicle. The loading bracket, thrust rod bracket and connecting seat are designed separately to meet the requirements of thrust rod brackets with different assembly hole distances, reducing the tooling manufacturing cost. The fixing seat is designed with an adjustable long hole to meet the assembly test requirements of axle housings of different height types.

[0030] Calculation of loading force: 1. Driving conditions: When the vehicle accelerates, the driving force on the axle assembly is F q , the force conditions of driving conditions are shown in the attached figure.

[0031] ……………… (1) Where: M max ——Maximum output torque of the axle, Nm; r k —tire rolling radius, m; According to the moment balance, the force acting on the upper thrust rod bracket of the bridge housing assembly is F1, and the force acting on one side of the lower thrust rod is F2.

[0032] Upper thrust rod bracket force: …… ... The lower thrust rod is subjected to unilateral force: ……………………(3) Where: a——The distance from the center of the upper thrust rod bracket mounting hole to the center of the axle housing; b——The distance from the center of the lower thrust rod bracket mounting hole to the center of the axle housing; (ii) Braking conditions: When the vehicle brakes suddenly, the braking force on the axle is F z The force conditions of the braking condition are shown in the attached figure.

[0033] …… ... Where: M 制 ——Maximum output torque of the axle, Nm; r k —tire rolling radius, m; According to the axle torque balance, the force acting on the upper thrust rod bracket of the bridge assembly is F1, and the force acting on one side of the lower thrust rod is F2.

[0034] Upper thrust rod bracket force: …… ... The lower thrust rod is subjected to unilateral force: …… ... Where: a——The distance between the center of the upper thrust rod bracket assembly hole and the center of the axle housing; b——The distance between the center of the lower thrust rod bracket assembly hole and the center of the axle housing; Compare the two working conditions in (1) and (2), the magnitude of the upper thrust rod bracket force formula (2) and (4), take the larger value as the upper thrust rod bracket test force value ± F1 as the test loading load; the magnitude of the lower thrust rod bracket force formula (3) and (5), take the larger value as the upper thrust rod bracket test force value ± F2 as the test loading load, and use a sine wave for loading.

[0035] The test frequency is 0.5~2Hz, and the test is considered qualified if no welds, bridge shell cracks, or bracket deformation occur within 200,000 tests.

Claims

1. A drive axle assembly thrust rod bracket test bench, characterized in that: It includes an axle tube clamp, a thrust rod bracket, a reaction seat, a cylinder hanger, a hydraulic cylinder and a control system. The thrust rod bracket includes an upper thrust rod bracket and a lower thrust rod bracket. The upper thrust rod bracket and the lower thrust rod bracket are respectively welded to the bridge housing assembly. When in use, the two ends of the bridge housing assembly to be tested are respectively arranged on the axle tube clamp, the hydraulic cylinder is arranged on the cylinder hanger, a sensor is arranged on the hydraulic cylinder, one end of the hydraulic cylinder is connected to the reaction seat; one end of the hydraulic cylinder is connected to a thrust rod bracket, and the other thrust rod brackets are respectively connected to the corresponding reaction seats, the hydraulic cylinder and the sensor are respectively connected to the control system, and the thrust rod bracket is subjected to a loading force test through the hydraulic cylinder; the test frequency is 0.5~2Hz, and it is considered qualified if there is no weld, bridge housing cracking and bracket deformation after 200,000 loading tests.

2. According to claim 1, a drive axle assembly thrust rod bracket test bench, characterized in that: When testing the upper thrust rod bracket, the other end of the hydraulic cylinder is connected to the upper thrust rod bracket, and the two lower thrust rod brackets are respectively connected to the corresponding reaction seats; when testing the lower thrust rod bracket, the other end of the hydraulic cylinder is connected to any one of the two lower thrust rod brackets, and the remaining lower thrust rod bracket and the upper thrust rod bracket are respectively connected to the corresponding reaction seats.

3. According to claim 1, a drive axle assembly thrust rod bracket test bench, characterized in that: A displacement sensor is installed in the hydraulic cylinder, and a force sensor is installed at the loading end of the servo hydraulic oil. The test loading force value is controlled by the control system, and force protection and displacement protection are set on the control system according to the test loading force value and deformation.

4. According to claim 1, a drive axle assembly thrust rod bracket test bench, characterized in that: A connecting plate and a thrust rod fixing bracket are arranged on the reaction seat, the thrust rod fixing bracket is arranged on the reaction seat through the connecting plate, strip-shaped bolt holes are opened on the mounting plate of the reaction seat, and bolt holes are arranged on the connecting plate.

5. According to claim 1, a drive axle assembly thrust rod bracket test bench, characterized in that: The axle tube clamp includes an upper axle tube seat, a lower axle tube seat, an axle tube seat connecting plate, a sliding module and a support plate. The upper axle tube seat is fixedly connected to the lower axle tube seat to form a clamp for clamping the two ends of the bridge housing assembly. The lower axle tube seat is arranged on the axle tube seat connecting plate, and an arc groove is provided on the axle tube seat connecting plate. The axle tube seat connecting plate is arranged on the sliding module, and the sliding module is arranged on the support plate. The support plate is provided with limit blocks at both ends of the sliding module.

6. According to claim 5, a drive axle assembly thrust rod bracket test bench, characterized in that: The sliding module includes a rolling skateboard and a skateboard seat. The rolling skateboard is provided with a semicircular shaft corresponding to the arc groove. The shaft tube seat connecting plate is arranged on the rolling skateboard. The arc groove of the shaft tube seat connecting plate is placed correspondingly on the semicircular shaft of the rolling skateboard. The shaft tube seat connecting plate can rotate back and forth repeatedly around the rolling skateboard. The rolling skateboard is placed on the skateboard seat. The skateboard seat is located between the limit blocks. The rolling skateboard can move left and right along the skateboard seat. The skateboard seat is fixedly arranged on the support plate.

7. According to claim 5, a drive axle assembly thrust rod bracket test bench, characterized in that: The sliding module includes a roller support plate and a roller. The roller support plate is provided with an arc-shaped roller groove, and the roller is placed in the roller groove. The arc-shaped groove of the shaft tube seat connecting plate is correspondingly placed on the roller. The shaft tube seat connecting plate can rotate back and forth around the roller, and the roller support plate is fixedly arranged on the support plate.

8. According to claim 5, a drive axle assembly thrust rod bracket test bench, characterized in that: The axle tube fixture also includes an axle tube clamp, and the two ends of the bridge housing assembly are clamped between the upper axle tube seat and the lower axle tube seat by the axle tube clamp.

Images