Intelligent early warning system and method applied to automobile transmission shaft

Abstract

The invention discloses an intelligent early warning system and method applied to an automobile transmission shaft, relates to the technical field of automobile transmission shaft alarm, and solves the technical problem that an automobile transmission shaft traditionally depends on a detection method of manual visual inspection and experience judgment and has significant limitation. Sensing equipment is installed on the transmission shaft according to the preset length, and performance data and working time of the transmission shaft are collected through the sensing equipment; evaluating the use state of the transmission shaft based on the performance data; if the use state of the transmission shaft is risky, an alarm is given out; if the use state of the transmission shaft is normal, data processing and analysis are carried out based on performance data and working duration, risk prediction of the transmission shaft is achieved, and the distance fault time is calculated to solve the problem; in this way, the detection method that the automobile transmission shaft depends on manual visual inspection and experience judgment for a long time is changed, and the limitation problem existing in a manual detection method is solved.

Description

Technical Field

[0001] The invention belongs to the field of automobile alarms, and relates to automobile transmission shaft alarm technology, in particular to an intelligent early warning system and method applied to automobile transmission shafts. Background Art

[0002] As a core component of the power transmission system, the performance of the automobile drive shaft directly affects the power output and driving safety of the vehicle. However, during long-term operation, the drive shaft will gradually accumulate damage due to repeated changes in torque loads, vibrations, and external environmental factors (such as corrosion and wear), including cracks, bending deformation, wear, and material fatigue. The traditional detection method that relies on manual visual inspection and empirical judgment has significant limitations, including:

[0003] High subjectivity: Manual testing relies heavily on the experience and skills of the inspector, which makes it difficult to achieve consistency and accuracy. This may lead to misjudgments or missed judgments, affecting diagnostic accuracy.

[0004] Inefficiency: Manual inspection is time-consuming and has limited coverage. It is unable to monitor the status of the drive shaft in real time and is difficult to meet the high-efficiency requirements of modern automobile maintenance.

[0005] Cost issues: Judgments based on experience may lead to unnecessary replacements, increasing the user's maintenance costs. It may also lead to ignoring parts that really need repair due to insufficient inspection, increasing potential risks.

[0006] Safety risks: If the potential risks of the drive shaft are not discovered and dealt with in a timely manner, it may suddenly break while driving, which will not only cause the vehicle to break down, but may also cause serious traffic accidents, posing a threat to passengers and other road users.

[0007] Therefore, there is an urgent need for an intelligent early warning system and method applied to an automobile transmission shaft to solve the above problems. Summary of the invention

[0008] The present invention aims to solve at least one of the technical problems existing in the prior art; to this end, the present invention proposes an intelligent early warning system and method for automobile drive shafts, which are used to solve the technical problem that the detection method of automobile drive shafts traditionally relies on manual visual inspection and experience judgment, and has significant limitations. The present invention installs a sensor device on the drive shaft according to a preset length, and collects the performance data and working time of the drive shaft through the sensor device; evaluates the use status of the drive shaft based on the performance data; issues an alarm if the use status of the drive shaft is at risk; and performs data processing and analysis based on the performance data and working time for a normal use status of the drive shaft, so as to predict the risk of the drive shaft and solve the above problems.

[0009] To achieve the above object, a first aspect of the present invention provides an intelligent early warning method for a vehicle transmission shaft, comprising:

[0010] A sensor device is installed on the transmission shaft according to a preset length, and the performance data and working time of the transmission shaft are collected through the sensor device; wherein the performance data includes the vertical deviation, rotation angle and input torque of the transmission shaft; the vertical deviation is the distance between the axis position of the transmission shaft and the initial axis position; the rotation angle is the rotation angle generated by the transmission shaft around its own axis after the torque of the reduction box is received; the input torque refers to the torque transmitted to the transmission shaft by the automobile reduction box;

[0011] Based on the performance data, determine whether the use status of the drive shaft is normal; if yes, predict the risk of drive shaft failure based on the performance data and working hours; if no, send a warning signal.

[0012] By installing sensing equipment on the drive shaft to collect the vertical deviation, rotation angle, torque and working time of the drive shaft, by comparing these data with the respective thresholds, it is determined whether the equipment is at risk, and an alarm is issued to remind the user if there is a risk, and the usage data is evaluated for the risk, and it is estimated how long it will take for the drive shaft to have problems based on the evaluation results. In summary, through this application, the usage data on the drive shaft can be collected in real time, and judgments and evaluations can be made based on the data, so that users can know more clearly the state of the car's drive shaft and its state in the future. It avoids the traditional detection method that relies on manual visual inspection and experience judgment, and greatly improves the intelligence and advancement of detection.

[0013] Preferably, evaluating the use status of the transmission shaft based on the performance data includes:

[0014] S1: judging whether the vertical deviation of the transmission shaft is greater than the vertical threshold value according to the vertical deviation, if yes, the use status is abnormal; if no, proceed to the next step;

[0015] S2: judging whether the rotation angle exceeds the angle threshold according to the rotation angle generated when the transmission shaft is subjected to torque; if yes, the use status is abnormal; if no, proceed to the next step;

[0016] S3: According to the deformation angle generated by the transmission shaft, determine whether the deformation angle exceeds the deformation angle threshold; if yes, the usage status is abnormal; if no, proceed to the next step; the deformation angle refers to the rotation angle generated by the transmission shaft after the torque disappears, and there is a residual rotation angle that cannot be recovered.

[0017] S4: Obtain a deformation coefficient based on the vertical deviation, rotation angle and deformation angle of the transmission shaft, and determine whether the deformation coefficient exceeds a deformation threshold. If yes, the use status is abnormal; if no, the use status is normal.

[0018] The transmission shaft will gradually accumulate damage due to repeated changes in torque loads, vibrations, and external environmental factors (such as corrosion and wear). The effects of these gradually accumulated damages can be reflected by vertical deviation, rotation angle, and deformation angle. Therefore, the performance of the transmission shaft is evaluated by vertical deviation, rotation angle, and deformation angle. This method simplifies the test data and obtains high accuracy results.

[0019] Preferably, the step of obtaining the angle threshold of the rotation angle includes:

[0020] S10: installing a sensor device on the transmission shaft according to a preset length, and collecting performance data and working time of the transmission shaft through the sensor device;

[0021] S11: dividing the input torque of the transmission shaft into a number of transmission sub-torques according to a preset torque step; obtaining the rotation angles of the input torques of the plurality of transmission shafts when the torques vary between zero and a peak torque through testing; repeating the testing until the transmission shaft breaks; the peak torque being the maximum input torque received by the transmission shaft;

[0022] S12: Record the data of the last test before each transmission shaft breaks, and obtain the fracture data by the rotation angle when the input torque of the transmission shaft changes between zero and peak torque;

[0023] S13: according to the fracture data, counting the transmission sub-rotation angles generated by each transmission shaft when the transmission sub-torques are the same in several transmission sub-torques; and calculating an average value according to the transmission sub-rotation angles to obtain an average sub-rotation angle.

[0024] S14: Obtaining a risk torsion angle curve according to a plurality of average sub-rotation angles and the corresponding transmission sub-torque fitting curves;

[0025] S15: inputting the torque applied to the transmission shaft into the risk torsion angle curve to obtain the rotation angle under the torque;

[0026] S16: The rotation angle is multiplied by the proportional coefficient A to obtain the angle threshold, where 0.8 <A≤1。

[0027] The rotation angle is an important indicator for evaluating the performance of the drive shaft. When the drive shaft is subjected to torque, a rotation angle will be generated. The rotation angle generated by the drive shaft when subjected to different torques is different. As the use time increases, the performance of the drive shaft will change. Therefore, by performing torque tests on several drive shafts, the data before the drive shaft breaks is obtained, and the risk torsion angle curve is obtained based on the data. The angle threshold is extracted through this risk torsion angle curve as an indicator for considering whether the drive shaft is safe. In this way, it is possible to determine whether the drive shaft is in a safe state, effectively eliminating the influence of factors such as wear, cracks, and cracking on the drive shaft.

[0028] Preferably, the step of obtaining the deformation angle threshold of the deformation angle includes:

[0029] S51: Perform a rotation test on several transmission shafts of the same model within a torque range to obtain the fracture deformation angles of several transmission shafts before they fracture;

[0030] S52: Calculate the average of several fracture deformation angles as the average deformation angle of the transmission shaft;

[0031] S53: Multiply the average deformation angle by the proportional coefficient to obtain a deformation angle threshold; wherein the proportional coefficient has a value range of [0.6, 1].

[0032] The deformation angle is the result of plastic deformation of the drive shaft. When the deformation angle appears, it means that the drive shaft has been damaged. However, it has little effect when used within the peak torque range. However, as the use time increases, the impact will gradually increase.

[0033] The deformation angle threshold is obtained by calculation. According to the deformation angle threshold, it is possible to evaluate whether the drive shaft is in a dangerous state, thus laying a basis for early warning of the drive shaft.

[0034] Preferably, the deformation coefficient is calculated by:

[0035] The vertical deviation, rotation angle and deformation angle of the transmission shaft are marked as CP, XZJ and XBJ respectively;

[0036] The deformation coefficient XBXS is obtained according to the formula XBXS={α1×CP+[α2×XZJ+α3×EXP(XBJ)]×π×R / 360} / L; α1, α2, and α3 are all proportional coefficients greater than zero, R is the diameter of the transmission shaft, and L is the distance of the transmission shaft collection point.

[0037] The deformation of the transmission shaft is mainly related to the vertical deviation, the rotation angle generated when subjected to torque, and the deformation angle. When these influencing factors are compared individually, the transmission shaft may not be in a dangerous state, but if multiple factors are interrelated, different effects will be produced. Therefore, it is clearer to evaluate the influence of multiple factors on the transmission shaft through the deformation coefficient.

[0038] Preferably, the steps of performing data processing and analysis based on performance data and working hours to predict the risk of the transmission shaft and calculate the time to failure include:

[0039] Record the input torque and corresponding rotation angle of the same transmission shaft at different working hours to obtain recorded data;

[0040] Dividing the peak torque received by the transmission shaft into a number of input sub-torques according to a specified torque step; and dividing the working duration of the transmission shaft into a number of working sub-durations according to a specified duration step; the peak torque is the maximum input torque received by the transmission shaft;

[0041] Extracting input torques and corresponding rotation angles of several working sub-durations from the recorded data to obtain recorded sub-data; and extracting several input sub-torques and corresponding rotation angles from the recorded sub-data of several working sub-durations;

[0042] Extracting a plurality of working sub-durations and corresponding rotation angles of the same input sub-torque from the plurality of input sub-torques, and acquiring a duration torsion curve based on the plurality of working sub-durations and corresponding rotation angles of the same input sub-torque;

[0043] Inputting different working sub-durations into several time-length torsion curves, obtaining several input sub-torques and corresponding rotation angles at the same working sub-duration, and obtaining a torsion angle curve based on the several input sub-torques and corresponding rotation angles at the same working sub-duration;

[0044] Based on the torsion angle curves of several working sub-durations, the risk sub-torque when the rotation angle is greater than the torsion angle threshold is obtained;

[0045] Extract the working sub-durations closest to the current working sub-duration when the risk sub-torques are less than the peak torque to obtain the risk duration; the risk duration is the working sub-duration when the risk sub-torque exceeds the peak torque;

[0046] Determine whether the risk duration is greater than the current working sub-duration; if yes, calculate the remaining working time of the transmission shaft; if no, perform alarm processing.

[0047] As the use time of the automobile drive shaft increases, the rotation angle generated at the same input torque is different. Based on this characteristic, a time-torsion curve is obtained, which shows how the rotation angle changes with time when the input torque is the same. Based on this curve, the rotation angle at future working time under the same input torque can be estimated. Based on several torsion curves, several input torques and corresponding rotation angles can be obtained. The torsion angle curves at different time lengths are obtained by fitting the curve. In this way, the rotation angle at future working time can be estimated to evaluate how long it will take for the drive shaft to have problems, and to remind users to take precautions in advance.

[0048] Preferably, the alarm processing steps are as follows:

[0049] S31: prompts the user that the transmission shaft is faulty and needs maintenance;

[0050] S32: Determine whether the user performs maintenance; if yes, the alarm is cleared; if no, proceed to S33;

[0051] S33: Determine whether the input sub-torque exceeds the risk torque threshold. If yes, adjust the input sub-torque to below the risk torque threshold; if no, do not perform any operation.

[0052] When an alarm sounds during the use of the drive shaft, the user will be reminded to deal with it first. However, due to some reasons, the fault may not be handled in time. At this time, risk control of the drive shaft is required to prevent the drive shaft from breaking during use and affecting safety. Therefore, the alarm will be prompted intermittently first, and after the user manually releases it, the alarm will still sound the next time the car is started; and when an alarm sounds, the input torque of the drive shaft will be reduced to protect the drive shaft. This can extend the service life of the vehicle's drive shaft and give users time to deal with the problem.

[0053] Preferably, the steps for obtaining the risk torque threshold are as follows:

[0054] When the risk duration is equal to the current working sub-duration, the torsion angle curve after the current working sub-duration is increased by one duration step is extracted, and the input sub-torque when the rotation angle is equal to the torsion angle threshold is obtained, and the input sub-torque is the risk torque threshold.

[0055] The risk torque threshold is an emergency protection measure when an alarm occurs in the drive shaft. Through this risk threshold, the input torque can be kept within a relatively safe range, thereby extending the service life of the drive shaft.

[0056] Preferably, the remaining working time of the transmission shaft is calculated based on the risk time and the current working sub-time.

[0057] S41: Subtract the risk duration from the current working sub-duration to obtain the remaining working duration;

[0058] S42: Based on each completion of a working sub-duration, data is updated, and steps S22 to S23 are repeated to update the remaining working duration.

[0059] The estimated service life of the drive shaft is evaluated based on the historical use of the drive shaft. If it is used more gently in the later stage, the service life of the drive shaft will be extended. Therefore, this value is constantly updated and changed.

[0060] Another aspect of the present invention provides an intelligent early warning system for a vehicle transmission shaft, comprising:

[0061] Data acquisition module: used to install a sensor device on the transmission shaft according to a preset length, and collect the performance data and working time of the transmission shaft through the sensor device; the sensor device is used to collect the vertical deviation, rotation angle, torque and working time of the transmission shaft; the rotation angle is the rotation angle generated by the transmission shaft around its own axis after the torque of the reduction box is received; the vertical deviation is the distance between the axis center position of the transmission shaft and the initialization axis center position;

[0062] Performance evaluation module: used to evaluate the use status of the transmission shaft based on performance data; the use status includes normal use and risk;

[0063] Risk prediction module: If the use status of the transmission shaft is at risk, an alarm will be issued. If the use status of the transmission shaft is normal, data processing and analysis will be performed based on performance data and working hours to predict the risk of the transmission shaft and calculate the time to failure.

[0064] Compared with the prior art, the beneficial effects of the present invention are: through this application, the performance data and working time of the drive shaft can be collected in real time, and the risk of the drive shaft can be evaluated according to the preset threshold, thereby avoiding problems during use; at the same time, the collected data is analyzed to estimate the time when the drive shaft will fail, and early warning prompts are given to avoid a lot of trouble; in this way, the detection method of automobile drive shafts that has long relied on manual visual inspection and experience judgment is changed, and the limitations of manual detection methods are solved. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0066] Figure 1 A schematic diagram of an intelligent early warning method applied to a vehicle transmission shaft according to an embodiment of the present invention;

[0067] Figure 2 A schematic diagram of risk estimation of a transmission shaft according to an embodiment of the present invention;

[0068] Figure 3 The figure is a schematic diagram of an intelligent early warning system applied to a vehicle transmission shaft according to an embodiment of the present invention. DETAILED DESCRIPTION

[0069] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0070] See also Figure 1 The first aspect of the present invention provides an intelligent early warning method for a vehicle transmission shaft, comprising:

[0071] S100: Install a sensing device on the drive shaft according to a preset length, and collect performance data and working time of the drive shaft through the sensing device; wherein the performance data includes the vertical deviation, rotation angle and input torque of the drive shaft; the vertical deviation is the distance between the axis position of the drive shaft and the initialization axis position; the rotation angle is the rotation angle generated by the drive shaft around its own axis after being subjected to the torque of the reduction box; the input torque refers to the torque transmitted to the drive shaft by the automobile reducer.

[0072] S200: Determine whether the use status of the transmission shaft is normal based on the performance data; if not, proceed to S300; if yes, proceed to S400.

[0073] Among them, judging whether the use status of the transmission shaft is normal based on the performance data includes:

[0074] S1: judging whether the vertical deviation of the transmission shaft is greater than the vertical threshold value according to the vertical deviation, if yes, the use status is abnormal; if no, proceed to the next step;

[0075] S2: judging whether the rotation angle exceeds the angle threshold according to the rotation angle generated when the transmission shaft is subjected to torque; if yes, the use status is abnormal; if no, proceed to the next step;

[0076] S3: According to the deformation angle generated by the transmission shaft, determine whether the deformation angle exceeds the deformation angle threshold; if yes, the usage status is abnormal; if no, proceed to the next step; the deformation angle refers to the rotation angle generated by the transmission shaft after the torque disappears, and there is a residual rotation angle that cannot be recovered.

[0077] S4: Obtain a deformation coefficient based on the vertical deviation, rotation angle and deformation angle of the transmission shaft, and determine whether the deformation coefficient exceeds a deformation threshold. If yes, the use status is abnormal; if no, the use status is normal.

[0078] The step of obtaining the angle threshold of the rotation angle includes:

[0079] S10: installing a sensor device on the transmission shaft according to a preset length, and collecting performance data and working time of the transmission shaft through the sensor device;

[0080] S11: dividing the input torque of the transmission shaft into a number of transmission sub-torques according to a preset torque step; obtaining the rotation angles of the input torques of the plurality of transmission shafts when the torques vary between zero and a peak torque through testing; repeating the testing until the transmission shaft breaks; the peak torque being the maximum input torque received by the transmission shaft;

[0081] S12: Record the data of the last test before each transmission shaft breaks, and obtain the fracture data by the rotation angle when the input torque of the transmission shaft changes between zero and peak torque;

[0082] S13: according to the fracture data, counting the transmission sub-rotation angles generated by each transmission shaft when the transmission sub-torques are the same in several transmission sub-torques; and calculating an average value according to the transmission sub-rotation angles to obtain an average sub-rotation angle.

[0083] S14: Obtaining a risk torsion angle curve according to a plurality of average sub-rotation angles and the corresponding transmission sub-torque fitting curves;

[0084] S15: inputting the torque applied to the transmission shaft into the risk torsion angle curve to obtain the rotation angle under the torque;

[0085] S16: The rotation angle is multiplied by the proportional coefficient A to obtain the angle threshold, where 0.8 <A≤1。

[0086] For example: Assume that the experimental data of three transmission shafts before fracture are obtained and the fracture data are:

[0087] Data of the first transmission shaft:

[0088] When the input torque is 100Nm, the rotation angle is 5°;

[0089] When the input torque is 200Nm, the rotation angle is 7°;

[0090] When the input torque is 300Nm, the rotation angle is 8°.

[0091] Second drive shaft data:

[0092] When the input torque is 100Nm, the rotation angle is 4°;

[0093] When the input torque is 200Nm, the rotation angle is 6°;

[0094] When the input torque is 300Nm, the rotation angle is 7°.

[0095] Data of the first transmission shaft:

[0096] When the input torque is 100Nm, the rotation angle is 6°;

[0097] When the input torque is 200Nm, the rotation angle is 7.5°;

[0098] When the input torque is 300Nm, the rotation angle is 8°.

[0099] Thus, the average data of the transmission shaft is obtained:

[0100] The rotation angle generated when the input torque is 100Nm is (5+4+6) / 3=5°;

[0101] The rotation angle generated when the input torque is 200Nm is (7+6+7.5) / 3=6.83°;

[0102] The rotation angle generated when the input torque is 300Nm is (8+7+8) / 3=7.67°;

[0103] Therefore, fitting is performed based on the average data of the transmission shaft to obtain the risk torsion angle curve corresponding to the input torque and rotation angle.

[0104] Assuming that the proportional coefficient A is 0.8, the input torque of the drive shaft during one use is 150 Nm, 150 Nm is input into the risk torsion curve to obtain the rotation angle under the torque; then 0.8 times the rotation angle is the angle threshold under the torque.

[0105] The step of obtaining the deformation angle threshold of the deformation angle includes:

[0106] S51: Perform a rotation test on several transmission shafts of the same model within a torque range to obtain the fracture deformation angles of several transmission shafts before they fracture;

[0107] S52: Calculate the average of several fracture deformation angles as the average deformation angle of the transmission shaft;

[0108] S53: Multiply the average deformation angle by the proportional coefficient to obtain a deformation angle threshold; wherein the proportional coefficient has a value range of [0.6, 1].

[0109] For example: Assume that the deformation angles of the three transmission shafts before breaking are:

[0110] The first deformation angle is 3.3°

[0111] The second deformation angle is 3.1°

[0112] The third deformation angle is 3.5°

[0113] Therefore, the average deformation angle of the transmission shaft is 3.3; assuming that the proportional coefficient B is 0.9, 2.97° is the deformation angle threshold.

[0114] The calculation method of deformation coefficient includes:

[0115] The vertical deviation, rotation angle and deformation angle of the transmission shaft are marked as CP, XZJ and XBJ respectively;

[0116] The deformation coefficient XBXS is obtained according to the formula XBXS={α1×CP+[α2×XZJ+α3×EXP(XBJ)]×π×R / 360} / L; α1, α2, and α3 are all proportional coefficients greater than zero, R is the diameter of the transmission shaft, and L is the distance of the transmission shaft collection point.

[0117] For example: Assume that α1, α2, and α3 are all 1, R is 10 mm, and L is 1000 mm;

[0118] The vertical deviation of the transmission shaft, the rotation angle when subjected to a torque of 100 Nm, and the deformation angle are obtained to be 1 mm, 5°, and 1° respectively;

[0119] Therefore, the deformation coefficient of the transmission shaft is XBXS=0.5.

[0120] Step S300: Sending a warning signal.

[0121] Step S400: Predicting the risk of transmission shaft failure based on performance data and working hours.

[0122] Among them, data processing and analysis are carried out based on performance data and working hours to realize risk prediction of the drive shaft, calculate the time to failure, and determine how long it will take for the car drive shaft to fail.

[0123] Curve fitting is performed based on the divided data and the corresponding rotation angles. The trend of the rotation angle changing with time and input torque is predicted through the fitted curve, so as to predict the time when the drive shaft will fail.

[0124] The present application installs a sensor device on the drive shaft according to a preset length, and collects the performance data and working time of the drive shaft through the sensor device; evaluates the use status of the drive shaft based on the performance data; the use status includes normal use and risk; if the use status of the drive shaft is risky, an alarm is issued; if the use status of the drive shaft is normal, the input torque and the working time are divided into steps, and a curve is fitted according to the divided data and the corresponding rotation angle, and the trend of the rotation angle changing with time and input torque is predicted by the fitted curve, so as to predict the time when the drive shaft fails.

[0125] See also Figure 2 , the transmission shaft risk assessment steps include:

[0126] S21: recording input torque and corresponding rotation angle of the same transmission shaft at different working hours to obtain recorded data;

[0127] S22: dividing the peak torque received by the transmission shaft into a plurality of input sub-torques according to a specified torque step; and dividing the working duration of the transmission shaft into a plurality of working sub-durations according to a specified duration step; the peak torque is the maximum input torque received by the transmission shaft;

[0128] For example: assuming that the force on the drive shaft is: 0-400Nm; according to the torque step of 100Nm, it is divided into: 100Nm, 200Nm, 300Nm and 400Nm; the working time of the drive shaft is 1000H, according to the time step of 100H, it is divided into 100H, 200H, 300H, 400H, 500H, 600H, 700H, 800H, 900H and 1000H.

[0129] S23: extracting input torques and corresponding rotation angles of several working sub-durations from the recorded data to obtain recorded sub-data; and extracting several input sub-torques and corresponding rotation angles from the recorded sub-data of several working sub-durations;

[0130] For example: record the rotation angle when the input torque is 100Nm, 200Nm, 300Nm, 400Nm and 400Nm when the working hours are 100H, 200H, 300H, 400H, 500H, 600H, 700H, 800H, 900H and 1000H respectively.

[0131] Assumptions:

[0132] When the working time is 100 hours, the rotation angles are 1°, 1.5°, 2° and 3° respectively when the input torque is 100Nm, 200Nm, 300Nm and 400Nm;

[0133] When the working time is 200 hours, the rotation angles are 1.5°, 2°, 2.5° and 3° respectively when the input torque is 100Nm, 200Nm, 300Nm and 400Nm;

[0134] When the working time is 300 hours, the rotation angles are 2°, 2.5°, 2.8° and 3.2° respectively when the input torque is 100Nm, 200Nm, 300Nm and 400Nm;

[0135] When the working time is 400H, the rotation angles at input torques of 100Nm, 200Nm, 300Nm and 400Nm are 2°, 2.6°, 2.9° and 3.2° respectively.

[0136] In this way, the change in rotation angle of the transmission shaft when it receives torque at various working hours is calculated.

[0137] S24: extracting a plurality of working sub-durations and corresponding rotation angles of the same input sub-torque from the plurality of input sub-torques, and acquiring a duration torsion curve based on the plurality of working sub-durations and corresponding rotation angles of the same input sub-torques by fitting.

[0138] For example:

[0139] When the input torque is 100Nm, the transmission shaft changes with the working time:

[0140] The working hours are: 100H, 200H, 300H, 400H;

[0141] The rotation angles are: 1°, 1.5°, 2°, and 2°.

[0142] When the input torque is 200Nm, the transmission shaft changes with the working time:

[0143] The working hours are: 100H, 200H, 300H, 400H;

[0144] The rotation angles are: 1.5°, 2°, 2.5°, and 2.6° respectively.

[0145] When the input torque is 300Nm, the transmission shaft changes with the working time:

[0146] The working hours are: 100H, 200H, 300H, 400H;

[0147] The rotation angles are: 2°, 2.5°, 2.8°, and 2.9° respectively.

[0148] When the input torque is 400Nm, the transmission shaft changes with the working time:

[0149] The working hours are: 100H, 200H, 300H, 400H;

[0150] The rotation angles are: 3°, 3°, 3.2°, 3.2° respectively.

[0151] Therefore, according to the change of the rotation angle at different working torques with the working time, the fitting curves at different working torques are obtained.

[0152] S25: inputting the current working time into a plurality of time torsion curves to obtain a plurality of input sub-torques and corresponding rotation angles, and obtaining a torsion angle curve based on the plurality of input sub-torques and corresponding rotation angles of the current working time;

[0153] For example:

[0154] Assume that the time-torque curve when the input torque is 100 Nm is curve 1;

[0155] Assume that the time-torque curve when the input torque is 200Nm is curve 2;

[0156] Assume that the time-torque curve when the input torque is 300Nm is curve 3;

[0157] Assume that the time-torque curve when the input torque is 400Nm is curve 4;

[0158] Therefore, when the working time is 100 hours, the working time is input into curve 1, curve 2, curve 3 and curve 4 respectively, and the rotation angles of 1°, 1.5°, 2° and 3° when the working input torque is 100Nm, 200Nm, 300Nm and 400Nm are obtained when the working time is 100H;

[0159] Therefore, when the working time is 200 hours, the working time is input into curve 1, curve 2, curve 3 and curve 4 respectively, and the rotation angles of 1.5°, 2°, 2.5° and 3° when the working input torque is 100Nm, 200Nm, 300Nm and 400Nm are obtained when the working time is 200 hours;

[0160] Therefore, when the working time is 1100H, the working time is input into curve 1, curve 2, curve 3 and curve 4 respectively, and the rotation angle when the working time is 1100H and the working input torque is 100Nm, 200Nm, 300Nm and 400Nm is obtained; and according to the data fitting curve, the torsion angle curve when the working time is 1100H is obtained.

[0161] Therefore, when the working sub-duration is 1200H, the working time is input into curve 1, curve 2, curve 3 and curve 4 respectively, and the rotation angle when the working time is 1200H and the working input torque is 100Nm, 200Nm, 300Nm and 400Nm is obtained; and according to the data fitting curve, the torsion angle curve when the working time is 1200H is obtained.

[0162] The torsion angle curves under different working sub-durations are obtained in the same way.

[0163] S26: based on the torsion angle curve of the current working time, obtaining the risk sub-torque when the rotation angle is greater than the torsion angle threshold;

[0164] For example: Assuming the torsion angle curve when the working sub-duration is 1200H, the risk sub-torque when the rotation angle is greater than the torsion angle threshold is 600Nm;

[0165] Assuming the torsion angle curve when the working sub-hour length is 2000H, the risk sub-torque when the rotation angle is greater than the torsion angle threshold is 380Nm;

[0166] S27: Determine the risk sub-torque

[0167] Is it less than the peak torque? If yes, proceed to S28; if no, proceed to S29;

[0168] S28: Determine whether the risk duration is greater than the current working sub-duration; if yes, calculate the remaining working time of the transmission shaft; if no, proceed to S30.

[0169] For example: assuming the torsion angle curve when the working sub-duration is 1200H, the risk sub-torque when the rotation angle is the torsion angle threshold is 600Nm, which is greater than the maximum torque of the input sub-torque of 400Nm; so the working sub-duration is increased by 1200H, and then the risk sub-torque is compared with the maximum torque of the input sub-torque.

[0170] When the working sub-time length is 2000H, the risk sub-torque is 380Nm, which is greater than the maximum torque of the input sub-torque of 400Nm; therefore, it is obtained that the transmission shaft will fail when the working sub-time length is 2000H.

[0171] Assuming that the current working sub-hour length is 1000 hours, we can obtain 2000-10000=1000 hours; that is, according to the current usage status, the transmission shaft will fail after 1000 hours.

[0172] S29: the current working time is increased by one time step and then the process goes to step S25;

[0173] S30: Perform alarm processing.

[0174] The steps for alarm processing are as follows:

[0175] S31: prompts the user that the transmission shaft is faulty and needs maintenance;

[0176] S32: Determine whether the user performs maintenance; if yes, the alarm is cleared; if no, proceed to the next step;

[0177] S32: Determine whether the input sub-torque exceeds the risk torque threshold. If yes, adjust the input sub-torque to below the risk torque threshold; if no, do not perform any operation.

[0178] By subdividing the input torque and working time, multiple groups of refined input torques and working time can be obtained. While keeping a set of input torques unchanged, multiple groups of torsion angles that change with the working time are obtained. A torsion angle curve is obtained through data fitting, and the value of the later torsion angle can be predicted through the torsion angle curve. According to this method, multiple torsion angle curves are obtained, and the torsion angle curves are obtained by extracting data with the same working time on these torsion curves for data fitting; the time when the risk of the drive shaft occurs is evaluated based on these fitting curves.

[0179] Part of the data in the above formula is calculated by removing the dimension and taking its numerical value. The formula is a formula closest to the actual situation obtained by software simulation of a large amount of collected data; the preset parameters and preset thresholds in the formula are set by technical personnel in this field according to actual conditions or obtained through simulation of a large amount of data.

[0180] The working principle of the present invention is as follows: a sensing device is installed on the drive shaft according to a preset length, and the performance data and working time of the drive shaft are collected through the sensing device. The performance data of the drive shaft is realized based on the principle that the data will be different when the drive shaft is damaged; the use status of the drive shaft is evaluated based on the performance data; the use status includes normal use and the existence of risks. At this time, the main thing is to evaluate the risks that have already occurred in the drive shaft, through the performance data evaluation of the drive shaft; if the use status of the drive shaft is that there is a risk, an alarm is issued; if the use status of the drive shaft is normal, data processing and analysis are performed based on the performance data and working time to realize the risk prediction of the drive shaft, and the time to failure is calculated to determine how long it will take for the automobile drive shaft to fail to solve the above problem.

[0181] The above embodiments are only used to illustrate the technical method of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical method of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical method of the present invention.

Claims

1. An intelligent early warning method applied to a vehicle transmission shaft, characterized in that: Installing a sensor device on the transmission shaft according to a preset length, and collecting performance data and working time of the transmission shaft through the sensor device; wherein the performance data includes vertical deviation, rotation angle and input torque of the transmission shaft; Based on the performance data, determine whether the use status of the drive shaft is normal; if yes, predict the risk of drive shaft failure based on the performance data and working hours; if no, send a warning signal.

2. The intelligent early warning method for automobile transmission shaft according to claim 1 is characterized in that: The determining whether the use status of the transmission shaft is normal based on the performance data includes: Determine whether any one of the vertical deviation, rotation angle, and deformation angle of the transmission shaft is greater than the corresponding threshold; if yes, determine that the use status is abnormal; if no, proceed to the next step; The deformation coefficient is calculated based on the vertical deviation, rotation angle and deformation angle of the transmission shaft; whether the deformation coefficient exceeds the deformation threshold is determined; if yes, the usage status is abnormal; if no, the usage status is normal; wherein, the deformation angle refers to an irreversible angular deviation that remains after the transmission shaft is subjected to a torque exceeding the elastic limit of its material, even if the external torque has been eliminated.

3. The intelligent early warning method for automobile transmission shaft according to claim 2 is characterized in that: The step of obtaining the angle threshold of the rotation angle comprises: S11: Performing a rotation test on a plurality of transmission shafts of the same model within a torque range, and extracting the test data before the plurality of transmission shafts break; wherein the torque range is from zero to peak torque, and the test data includes torque and corresponding rotation angle; the peak torque is the maximum input torque received by the transmission shaft; S12: Divide the peak torque of the transmission shaft into a number of transmission sub-torques according to a preset torque step; extract a number of rotation angles corresponding to each transmission sub-torque from corresponding test data of a number of transmission shafts of the same model; S13: Calculate the average of several rotation angles corresponding to the transmission sub-torque as the average sub-rotation angle of the transmission sub-torque; and obtain a risk rotation angle curve based on the fitting of the several transmission sub-torques and the corresponding average sub-rotation angles; S14: Substitute the input torque of the transmission shaft into the risk rotation angle curve to obtain the corresponding rotation angle; multiply the rotation angle by the proportional coefficient to obtain the angle threshold; wherein the value range of the proportional coefficient is [0.8, 1].

4. The intelligent early warning method for automobile transmission shaft according to claim 2 is characterized in that: The step of obtaining the deformation angle threshold of the deformation angle comprises: S51: Perform a rotation test on several transmission shafts of the same model within a torque range to obtain the fracture deformation angles of several transmission shafts before they fracture; S52: Calculate the average of several fracture deformation angles as the average deformation angle of the transmission shaft; S53: Multiply the average deformation angle by the proportional coefficient to obtain a deformation angle threshold; wherein the proportional coefficient has a value range of [0.6, 1].

5. The intelligent early warning method for automobile transmission shaft according to claim 2 is characterized in that: The calculation method of the deformation coefficient includes: The vertical deviation, rotation angle and deformation angle of the transmission shaft are marked as CP, XZJ and XBJ respectively; The deformation coefficient XBXS is obtained according to the formula XBXS={α1×CP+[α2×XZJ+α3×EXP(XBJ)]×π×R / 360} / L; α1, α2, and α3 are all proportional coefficients greater than zero, R is the diameter of the transmission shaft, and L is the distance of the transmission shaft collection point.

6. The intelligent early warning method for automobile transmission shaft according to claim 1 is characterized in that: The steps of performing data processing and analysis based on performance data and working hours to predict the risk of the transmission shaft and calculate the time to failure include: Record the input torque and corresponding rotation angle of the same transmission shaft at different working hours to obtain recorded data; Dividing the peak torque received by the transmission shaft into a number of input sub-torques according to a specified torque step; and dividing the working duration of the transmission shaft into a number of working sub-durations according to a specified duration step; the peak torque is the maximum input torque received by the transmission shaft; Extracting input torques and corresponding rotation angles of several working sub-durations from the recorded data to obtain recorded sub-data; and extracting several input sub-torques and corresponding rotation angles from the recorded sub-data of several working sub-durations; Extracting a plurality of working sub-durations and corresponding rotation angles of the same input sub-torque from the plurality of input sub-torques, and acquiring a duration torsion curve based on the plurality of working sub-durations and corresponding rotation angles of the same input sub-torque; Inputting different working sub-durations into several time-length torsion curves, obtaining several input sub-torques and corresponding rotation angles at the same working sub-duration, and obtaining a torsion angle curve based on the several input sub-torques and corresponding rotation angles at the same working sub-duration; Based on the torsion angle curves of several working sub-durations, the risk sub-torque when the rotation angle is greater than the torsion angle threshold is obtained; Extract the working sub-durations closest to the current working sub-duration when the risk sub-torques are less than the peak torque to obtain the risk duration; the risk duration is the working sub-duration when the risk sub-torque exceeds the peak torque; Determine whether the risk duration is greater than the current working sub-duration; if yes, calculate the remaining working time of the transmission shaft; if no, perform alarm processing.

7. The intelligent early warning method for automobile transmission shaft according to claim 6 is characterized in that: The alarm processing comprises: S31: prompts the user that the transmission shaft is faulty and needs maintenance; S32: Determine whether the user performs maintenance; if yes, the alarm is cleared; if no, proceed to S33; S33: Determine whether the input sub-torque exceeds the risk torque threshold. If yes, adjust the input sub-torque to below the risk torque threshold; if no, do not perform any operation.

8. The intelligent early warning method for automobile transmission shaft according to claim 7 is characterized in that: The steps for obtaining the risk torque threshold are as follows: When the risk duration is equal to the current working sub-duration, the torsion angle curve after the current working sub-duration is increased by one duration step is extracted, and the input sub-torque when the rotation angle is greater than the torsion angle threshold is obtained according to the torsion angle curve. The input sub-torque is the risk torque threshold.

9. An intelligent early warning system applied to automobile transmission shaft, characterized in that: include: Data acquisition module: Install a sensor device on the transmission shaft according to a preset length, and collect the performance data and working time of the transmission shaft through the sensor device; wherein the performance data includes the vertical deviation, rotation angle and input torque of the transmission shaft; the rotation angle is the rotation angle generated by the transmission shaft around its own axis after receiving the torque of the reduction box; the vertical deviation is the distance between the axis center position of the transmission shaft and the initialization axis center position; Performance evaluation module: judge the use status of the transmission shaft based on performance data; Risk prediction module: predicts the risk of drive shaft failure based on performance data and working hours.

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