High-efficiency steering engine assembly test system

Abstract

The invention relates to a high-efficiency steering engine assembly test system, belongs to the technical field of steering engine assembly, and solves the problems of poor flexibility, low efficiency and large debugging workload of a mechanical assembly debugging process of an existing steering engine in the prior art. The welding-free wiring module is used for connecting a displacement sensor and a motor of the mechanically assembled steering engine, receiving displacement feedback information output by the displacement sensor and outputting a driving signal to the motor; the test mode selection module is used for selecting a test mode of the steering engine, and the test mode comprises a step test, a running-in test and a small instruction frequency sweep test; the digital processor is used for performing motor closed-loop control according to a test function corresponding to the test mode and the displacement feedback information, and outputting a generated control quantity to the motor driver; and the motor driver generates a driving signal based on the control quantity output by the digital processor and transmits the driving signal to the motor through the welding-free wiring module. Quality control of production links is achieved, rework amount is reduced, production efficiency is improved, batch production of products is facilitated, sufficient stability allowance is reserved for performance debugging of the whole machine, and product reliability is improved.

Description

Technical Field

[0001] The invention relates to the technical field of steering gear assembly, and in particular to a high-efficiency steering gear assembly test system. Background Art

[0002] A servo is a high-precision position servo system used to drive the deflection of the air rudder to achieve aircraft attitude control. In particular, electric servos have the advantages of small size, high efficiency, long life, and long maintenance-free cycle, and are widely used. The core components of electric servos include motors, transmission mechanisms, and controllers. Any abnormality in any component will affect the performance of the entire machine, resulting in rework and affecting production efficiency. Especially for micro-sized electric servos, the performance of the entire machine is highly sensitive to the performance of components and assembly quality. There is a problem that the controller software parameter adjustment cannot accommodate the differences in structural components, resulting in a decrease in the performance of the entire machine.

[0003] The existing production process mainly includes two debugging processes. One is the transfer of steering gear mechanical assembly to electrical assembly and then to whole machine debugging. When the debugging performance of the whole machine does not meet the expectations, the mechanical assembly needs to be reworked, and the rework of the mechanical assembly requires the rework of the electrical assembly as well. The rework workload is large, the production efficiency is low, and it is not conducive to mass production. The other is the transfer of steering gear mechanical assembly to electrical assembly and then to whole machine debugging. When the debugging performance of the whole machine does not meet the expectations, the controller parameters are abnormally amplified to accommodate the mechanical assembly errors as much as possible and avoid rework. The disadvantage is that the abnormally large control parameters affect the stability of the controller and there is a risk of instability of the whole machine.

[0004] Therefore, the existing steering gear mechanical assembly and debugging process has the disadvantages of poor flexibility, low efficiency and large debugging workload. Summary of the invention

[0005] In view of the above analysis, the embodiment of the present invention aims to provide a high-efficiency steering gear assembly and testing system to solve the problems of poor flexibility, low efficiency and large debugging workload in the existing steering gear mechanical assembly and debugging process.

[0006] An embodiment of the present invention provides a high-efficiency steering gear assembly and testing system, the system comprising:

[0007] The welding-free wiring module is used to connect the displacement sensor and the motor of the mechanically assembled servo, receive the displacement feedback information output by the displacement sensor, and output a driving signal to the motor;

[0008] A test mode selection module, used to select a test mode of the servo, wherein the test modes include a step test, a running-in test, and a small command sweep test;

[0009] A digital processor performs closed-loop control of the motor according to the test function corresponding to the test mode and the displacement feedback information, and outputs the generated control quantity to the motor driver;

[0010] The motor driver generates a drive signal based on the control quantity output by the digital processor and transmits it to the motor through a solder-free wiring module.

[0011] Based on the further improvement of the above system, the system further comprises an input module, the input module is connected to the digital processor and is used to input a test function corresponding to the test mode;

[0012] The test function of the step test is:

[0013]

[0014] Among them, A1 is the amplitude, T1 is the step time, T2 is the zero return time, and y1(t1) is the target displacement position at time t1;

[0015] The test function of the running-in test is:

[0016]

[0017] Where A2 is the amplitude, N is the period, f2 is the frequency, t2 is the time required for f2 to execute one cycle, and y2(t2) is the target displacement position at time t2;

[0018] The test function of the small instruction sweep frequency test is:

[0019]

[0020] Wherein, A3 is the amplitude, f3 is the frequency, f3=1, 2, ..., N, N is the maximum frequency allowed by the servo, t3 is the time required for f3 to execute a cycle, T n is the sum of the time it takes for the frequency f3 to be executed from 1 to N, and y3(t3) is the target displacement position at time t3.

[0021] Based on the further improvement of the above system, the system further comprises a display module, which is connected to the digital processor and comprises a plurality of LED lights and a buzzer for displaying the test results;

[0022] When the test mode is a step test, the digital processor calculates the average value of the displacement feedback information after the step is maintained for a certain period of time. If the absolute value of the deviation between the average value and the amplitude A1 is less than the first preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms;

[0023] When the test mode is a running-in test, the digital processor calculates the integral of the absolute value of the error between the displacement feedback information of a certain number of cycles and the test function y2(t2). When it is less than a second preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms;

[0024] When the test mode is a small instruction sweep test, the digital processor obtains the maximum value of the displacement feedback information in Tn, and calculates the tracking amplitude based on the maximum value. When the tracking amplitude is less than the third preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms; wherein, the tracking amplitude Mtemp is:

[0025]

[0026] Among them, SineSweepMaxAmpvalue is the maximum value of the displacement feedback information, and MinAmplitude is the minimum required value of the insensitive area of ​​the servo.

[0027] Based on the further improvement of the above system, the control quantity output3 is generated as follows:

[0028] outPut1=Kv*(Kp*(Ref-Fed)-Kf*Fed′+Ref′)-Fed″+Ref″,

[0029]

[0030] output3=LimitDesign(LF(s)*output2),

[0031] Among them, outPut1 and outPut2 are intermediate variables, Fed is displacement feedback information, Kv is the differential control coefficient, Kp is the displacement control coefficient, Kf is the feedback adaptive adjustment coefficient, Fed′ is the differential of Fed, Ref′ is the differential of Ref, Fed″ is the second differential of Fed, Ref″ is the second differential of Ref, Ka is the torque control coefficient, Ki is the integral control coefficient, Ref is the target displacement position output by the test function in the current execution cycle, MaxDesignSpeed is the maximum operating speed of the servo; fun() is a function, when the function input is greater than 2, the function output is equal to 2, when the function input is less than 0.5, the function output is equal to 0.5, in other cases, the function output is equal to the input; LimitDesign() is a limit function, when the input is less than -0.99, the output is equal to -0.99, when the input is greater than 0.99, the output is equal to 0.99, in other cases, the function output is equal to the input; LF(s) is the transfer function of the low-pass filter, and its calculation method is as follows,

[0032]

[0033] s is the complex variable of the Laplace transform.

[0034] Based on the further improvement of the above system, the differential control coefficient Kv, the displacement control coefficient Kp, the torque control coefficient Ka, and the integral control coefficient i are determined based on the trial-and-error method or the simulation method.

[0035] Based on the further improvement of the above system, for each control cycle, the feedback adaptive adjustment coefficient Kf is determined in the following manner:

[0036] A1: Calculate the tracking error E and the tracking speed V based on the target displacement position and the displacement feedback information;

[0037] A2: Construct a tracking error segment based on the maximum mechanical stroke of the servo and a tracking speed segment based on the maximum operating speed. Specifically:

[0038] The tracking error segment includes E1 - E2, E2 - E3, E3 - E4, and the tracking speed segment includes V1 - V2, V1 - V2, V3 - V4. Among them, 0 < E1 < E2 < E3 < E4 < 2Emax, 0 < V1 < V2 < V3 < V4 < Vmax. After determining E1 and E4, E2 and E3 are equally divided based on E1 and E4. After determining V1 and V4, V2 and V3 are equally divided based on V1 and V4. Emax is the maximum mechanical stroke of the servo, and Vmax is the maximum operating speed;

[0039] Construct piecewise adjustment coefficients P1, P2, and P3, where 0 < P1, P2, P3 < 1;

[0040] A3: Calculating a speed adjustment coefficient, an error adjustment coefficient, and a bias coefficient based on the tracked error segment, the tracked speed segment, and the segment adjustment coefficient;

[0041] A4: Calculate the first intermediate variable value Etemp based on the relationship between the tracking error E and the error range endpoint values ​​E1 and E4, and calculate the second intermediate variable value Vtemp based on the relationship between the tracking speed V and the speed range endpoint values ​​V1 and V4;

[0042] A5: Calculate the third intermediate variable value Econ based on the relationship between the first intermediate variable value Etemp and the intermediate values ​​E2 and E3 of the error range, and calculate the fourth intermediate variable value Vcon based on the relationship between the second intermediate variable value Vtemp and the intermediate values ​​V2 and V3 of the speed range;

[0043] A6: The fifth intermediate variable value EVcon ​​is calculated based on the third intermediate variable value Econ and the fourth intermediate variable value Vcon, and the value of the feedback adaptive adjustment coefficient Kf is obtained based on the fifth intermediate variable value EVcon, the speed adjustment coefficient, the error adjustment coefficient, the bias coefficient, the first intermediate variable value Etemp and the second intermediate variable value Vtemp.

[0044] Based on the further improvement of the above system, the speed adjustment coefficient, the error adjustment coefficient and the bias coefficient are calculated based on the tracked error segment and the tracked speed segment, including:

[0045] The speed adjustment coefficients are a11, a12, a13, a21, a22, a23, a31, a32, and a33, and the specific calculation method is:

[0046]

[0047] The error adjustment coefficients are b11, b12, b13, b21, b22, b23, b31, b32, b33, and are specifically calculated as follows:

[0048]

[0049] The bias coefficients are c11, c12, c13, c21, c22, c23, c31, c32, c33, and are specifically calculated as follows:

[0050] c11=1-a11*V1-b11*E1, c12=1+P1-a12*V2-b12*E1,

[0051] c13=1+P1-P2-a13*V3-b13*E1, c21=1-P1-a21*V1-b21*E2,

[0052] c22=1-a22*V2-b22*E2, c23=1+P1-a23*V3-b23*E2,

[0053] c21=1-P1-P2-a31*V1-b21*E3, c32=1-P1-a32*V2-b32*E3,

[0054] c33=1-a33*V3-b33*E3.

[0055] Based on the further improvement of the above system, the calculation of the first intermediate variable value Etemp based on the relationship between the tracking error E and the error range endpoint values ​​E1 and E4, and the calculation of the second intermediate variable value Vtemp based on the relationship between the tracking speed V and the speed range endpoint values ​​V1 and V4 include:

[0056] If the tracking error E is less than E1 or greater than the negative of E1, then Etemp = E1; if the tracking error E is greater than E4 or less than the negative of E4, then Etemp = E4; otherwise, Etemp = |E|, where || is the absolute value;

[0057] If the tracking speed V is less than V1 or greater than the negative of V1, then Vtemp=V1; if the tracking error V is greater than V4 or less than the negative of V4, then Vtemp=V4; otherwise, Vtemp=|V|.

[0058] Based on the further improvement of the above system, the calculation of the third intermediate variable value Econ based on the relationship between the first intermediate variable value Etemp and the intermediate values ​​E2 and E3 of the error range, and the calculation of the fourth intermediate variable value Vcon based on the relationship between the second intermediate variable value Vtemp and the intermediate values ​​V2 and V3 of the speed range include:

[0059] If Etemp is greater than E3, then Econ = 30, if Etemp is greater than E2, then Econ = 20, otherwise, Econ = 10;

[0060] If Vtemp is greater than V3, then Vcon=3; if Vtemp is greater than E2, then Vcon=2; otherwise, Vcon=1.

[0061] Based on the further improvement of the above system, the fifth intermediate variable value EVcon ​​is calculated based on the third intermediate variable value Econ and the fourth intermediate variable value Vcon, including:

[0062] EVcon=Econ+Vcon;

[0063] The value of the feedback adaptive adjustment coefficient Kf obtained based on the fifth intermediate variable value EVcon, the speed adjustment coefficient, the error adjustment coefficient, the bias coefficient, the first intermediate variable value Etemp and the second intermediate variable value Vtemp includes:

[0064] If EVcon=11, then Kf=a11*Vtemp+b11*Etemp+c11;

[0065] If EVcon=12, then Kf=a12*Vtemp+b12*Etemp+c12;

[0066] If EVcon=13, then Kf=a13*Vtemp+b13*Etemp+c13;

[0067] If EVcon=21, then Kf=a21*Vtemp+b21*Etemp+c21;

[0068] If EVcon=22, then Kf=a22*Vtemp+b22*Etemp+c22;

[0069] If EVcon=23, then Kf=a23*Vtemp+b23*Etemp+c23;

[0070] If EVcon=31, then Kf=a31*Vtemp+b31*Etemp+c31;

[0071] If EVcon=32, then Kf=a32*Vtemp+b32*Etemp+c32;

[0072] If EVcon=33, then Kf=a33*Vtemp+b33*Etemp+c33.

[0073] Compared with the prior art, the present invention can achieve at least one of the following beneficial effects:

[0074] 1. The high-efficiency steering gear assembly and testing system provided by the present invention can realize the steering gear assembly and debugging at the same time. If the steering gear in the previous assembly link does not meet the test requirements, it will be reworked immediately, and then transferred to the next link after passing the test. This realizes the quality control of the production link, reduces the amount of rework, improves the production efficiency, facilitates the mass production of products, leaves sufficient stable margin for the performance debugging of the whole machine, and improves the product reliability.

[0075] 2. The high-efficiency steering gear assembly test system provided by the present invention integrates three test methods, namely step test, running-in test and small instruction sweep test, into the same test system. The test function that meets the experimental requirements is input into the digital processor through the input module. The system has high flexibility and realizes customized steering gear assembly test, which can meet the assembly test requirements of different types of micro-steering gears. In addition, the present invention directly inputs the test function into the digital processor to generate the control quantity. Compared with the traditional test method (i.e., the external frame-by-frame input test signal), the test system provided by the present invention can greatly improve the test efficiency.

[0076] 3. The high-efficiency steering gear assembly test system provided by the present invention provides a calculation method for the feedback adaptive adjustment coefficient, further improving the accuracy of the output control quantity, thereby being able to obtain more accurate displacement feedback information of the steering gear motor to be tested.

[0077] In the present invention, the above-mentioned technical solutions can also be combined with each other to achieve more preferred combination solutions. Other features and advantages of the present invention will be described in the subsequent description, and some advantages can become obvious from the description, or can be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained through the contents particularly pointed out in the description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0078] The accompanying drawings are only used for the purpose of illustrating specific embodiments and are not to be considered as limiting the present invention. In the entire drawings, the same reference symbols represent the same components;

[0079] Figure 1 This is an example diagram of a high-efficiency steering gear assembly test system in an embodiment of the present invention;

[0080] Figure 2 This is an example diagram of a method for calculating a feedback adaptive adjustment coefficient in an embodiment of the present invention. DETAILED DESCRIPTION

[0081] The preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not used to limit the scope of the present invention.

[0082] Mechanical assembly refers to assembling the main components such as the motor, steering gear frame, transmission mechanism, displacement sensor, etc. together to make the steering gear mechanical motion function structure complete. In view of the defects existing in the steering gear assembly process, the present invention designs a system for testing and adjusting the steering gear mechanical assembly to overcome the problems of poor flexibility, low efficiency and large debugging workload in the steering gear mechanical assembly and debugging process in the prior art.

[0083] A specific embodiment of the present invention discloses a high-efficiency steering gear assembly test system, such as Figure 1 As shown, including:

[0084] The welding-free wiring module is used to connect the displacement sensor and the motor of the mechanically assembled servo, receive the displacement feedback information output by the displacement sensor, and output a driving signal to the motor;

[0085] A test mode selection module, used to select a test mode of the servo, wherein the test modes include a step test, a running-in test, and a small command sweep test;

[0086] A digital processor performs closed-loop control of the motor according to the test function corresponding to the test mode and the displacement feedback information, and outputs the generated control quantity to the motor driver;

[0087] The motor driver generates a drive signal based on the control quantity output by the digital processor and transmits it to the motor through a solder-free wiring module.

[0088] In one embodiment, the system further comprises:

[0089] an input module, the input module being connected to the digital processor and being used for inputting a test function corresponding to the test mode;

[0090] A display module, which is connected to the digital processor and includes a plurality of LED lights and a buzzer, and is used to display the test results;

[0091] Power Module( Figure 1 The power supply port is connected to an external power supply through two 0.15mm 2 The red and black wires are connected, the red wire is the positive power supply, the black wire is the negative power supply, and the power module supplies power to the entire test system.

[0092] For the solder-free wiring module, the solder-free wiring port consists of five 0.15mm 2 The end of the wire is connected to an alligator clip to achieve welding-free wiring. Labels are made on the wire: displacement positive, displacement ground, displacement output, motor positive and motor negative, which are respectively connected to the displacement positive, displacement ground, displacement output, motor positive and motor negative of the displacement sensor.

[0093] The test mode selection module includes three dip switches and one push button switch. The three dip switches correspond to step test, running-in test and small instruction sweep test respectively. When the dip switch is turned ON, the corresponding test mode is selected. When no dip switch is turned ON or multiple dip switches are turned ON, all test modes are invalid, the motor driver has no output, and the motor is not controlled. The push button switch is normally open, which is connected when pressed by external force and automatically pops up and disconnects when there is no external force. When the button is turned on, a performance test selected by the dip switch is triggered. During the test, the button is invalid and the change of the dip switch is invalid.

[0094] Among them, the step test is used for the initial test of the servo performance, to check whether the transmission mechanism is stuck, and to determine whether the transmission mechanism needs to be replaced for mechanical assembly rework. The running-in test is used for the running-in of the servo transmission mechanism to release the mechanical assembly stress of the transmission mechanism. If the test requirements are not met, the shim is adjusted. The small command sweep frequency test is used to test the small command amplitude-frequency characteristics and check the tightness of the mechanical assembly. If the test requirements are not met, the shim is adjusted.

[0095] For the digital processor, it is implemented based on a single-chip microcomputer, ARM or DSP digital controller, runs an embedded control program, has IO input and output control, AD acquisition, PWM output and timing interrupt functions, acquires the state of the dip switch selected in the test mode selection module through the IO input port, and selects the corresponding test program.

[0096] Among them, the switch state of the key button of the test mode selection port is collected through the IO input port. When the key button is turned on, an external interrupt is triggered, and the test process of the three test modes is started in the external interrupt handler. When the test is in progress, the test start command is ignored; the LED light and buzzer of the test performance display port are controlled through serial communication and ordinary Io output ports. The digital processor collects the displacement sensor feedback value input by the welding-free wiring port through the port in the AD acquisition welding-free wiring module, which is used for the closed-loop control of the servo position. The digital processor runs the control program according to the current test instruction and the servo displacement feedback, generates the motor control quantity, and outputs it to the motor driver through the PWM port. Exemplarily, the digital processor performs accurate control cycle timing through a timer, and performs servo displacement sensor acquisition and motor control quantity calculation and PWM output every 0.5ms.

[0097] Among them, the control quantity output3 is obtained by the following calculation method:

[0098] outPut1=Kv*(Kp*(Ref-Fed)-Kf*Fed′+Ref′)-Fed″+Ref″,

[0099]

[0100] outPut3=LimitDesign(LF(s)*output2),

[0101] Among them, output1 and outPut2 are intermediate variables, Fed is the displacement feedback information, Kv is the differential control coefficient, Kp is the displacement control coefficient, Kf is the feedback adaptive adjustment coefficient, Fed′ is the differential of Fed, Ref′ is the differential of Ref, Fed″ is the secondary differential of Fed, Ref″ is the secondary differential of Ref, Ka is the torque control coefficient, Ki is the integral control coefficient, Ref is the target displacement position output by the current execution cycle test function, and MaxDesignSpeed ​​is the maximum operating speed of the servo; fun() is a function. When the function input is greater than 2, the function output is equal to 2. When the function input is less than 0.5, the function output is equal to 0.5. In other cases, the function output is equal to the input; LimitDesign() is a limiting function. When the input is less than -0.99, the output is equal to -0.99. When the input is greater than 0.99, the output is equal to 0.99. In other cases, the function output is equal to the input; LF(s) is the low-pass filter transfer function, which is calculated as follows,

[0102]

[0103] s is the complex variable of Laplace transform.

[0104] The differential control coefficient Kv, the displacement control coefficient Kp, the torque control coefficient Ka, and the integral control coefficient Ki are determined based on the trial and error method or the simulation method. Among them, the trial and error method and the simulation method are common knowledge in the art, and the present invention does not specifically limit them, as long as the parameter values ​​obtained by the above two methods can meet the test requirements of the steering gear assembly test.

[0105] For each control cycle, Figure 2 As shown, the feedback adaptive adjustment coefficient Kf is determined in the following way:

[0106] A1: Calculate the tracking error E and tracking speed V based on the target displacement position and displacement feedback information.

[0107] A2: Construct the tracking error segment based on the maximum mechanical travel of the servo, and construct the tracking speed segment based on the maximum operating speed, specifically:

[0108] The tracking error segments include E1 - E2, E2 - E3, and E3 - E4, and the tracking speed segments include V1 - V2, V1 - V2, and V3 - V4. Among them, 0 < E1 < E2 < E3 < E4 < 2Emax, 0 < V1 < V2 < V3 < V4 < Vmax. After determining E1 and E4, E2 and E3 are obtained by equidistant division based on E1 and E4. After determining V1 and V4, V2 and V3 are obtained by equidistant division based on V1 and V4. Emax is the maximum mechanical stroke of the servo, and Vmax is the maximum operating speed of the servo;

[0109] Construct segmented adjustment coefficients P1, P2, and P3, where 0 < P1, P2, P3 < 1.

[0110] A3: Calculate the speed adjustment coefficient, error adjustment coefficient, and offset coefficient based on the tracking error segments, the tracking speed segments, and the segmented adjustment coefficients, including:

[0111] The speed adjustment coefficients are a11, a12, a13, a21, a22, a23, a31, a32, and a33, and the specific calculation method is:

[0112]

[0113] The error adjustment coefficients are b11, b12, b13, b21, b22, b23, b31, b32, and b33, and the specific calculation method is:

[0114]

[0115] The offset coefficients are c11, c12, c13, c21, c22, c23, c31, c32, and c33, and the specific calculation method is:

[0116] c11 = 1 - a11 * V1 - b11 * E1, c12 = 1 + P1 - a12 * V2 - b12 * E1,

[0117] c13 = 1 + P1 - P2 - a13 * V3 - b13 * E1, c21 = 1 - P1 - a21 * V1 - b21 * E2,

[0118] c22 = 1 - a22 * V2 - b22 * E2, c23 = 1 + P1 - a23 * V3 - b23 * E2,

[0119] c21 = 1 - P1 - P2 - a31 * V1 - b21 * E3, c32 = 1 - P1 - a32 * V2 - b32 * E3,

[0120] c33 = 1 - a33 * V3 - b33 * E3.

[0121] A4: Calculating a first intermediate variable value Etemp based on the relationship between the tracking error E and the error range endpoint values ​​E1 and E4, and calculating a second intermediate variable value Vtemp based on the relationship between the tracking speed V and the speed range endpoint values ​​V1 and V4, including:

[0122] If the tracking error E is less than E1 or greater than the negative of E1, then Etemp = E1; if the tracking error E is greater than E4 or less than the negative of E4, then Etemp = E4; otherwise, Etemp = |E|, where || is the calculated absolute value;

[0123] If the tracking speed V is less than V1 or greater than the negative of V1, then Vtemp=V1; if the tracking error V is greater than V4 or less than the negative of V4, then Vtemp=V4; otherwise, Vtemp=|V|.

[0124] A5: Calculating the third intermediate variable value Econ based on the relationship between the first intermediate variable value Etemp and the intermediate values ​​E2 and E3 of the error range, and calculating the fourth intermediate variable value Vcon based on the relationship between the second intermediate variable value Vtemp and the intermediate values ​​V2 and V3 of the speed range, including:

[0125] If Etemp is greater than E3, then Econ = 30, if Etemp is greater than E2, then Econ = 20, otherwise, Econ = 10;

[0126] If Vtemp is greater than V3, then Vcon=3; if Vtemp is greater than E2, then Vcon=2; otherwise, Vcon=1.

[0127] A6: A fifth intermediate variable value EVcon ​​is calculated based on the third intermediate variable value Econ and the fourth intermediate variable value Vcon, and a value of a feedback adaptive adjustment coefficient Kf is obtained based on the fifth intermediate variable value EVcon, the speed adjustment coefficient, the error adjustment coefficient, the bias coefficient, the first intermediate variable value Etemp, and the second intermediate variable value Vtemp, including:

[0128] The calculation of the fifth intermediate variable value EVcon ​​based on the third intermediate variable value Econ and the fourth intermediate variable value Vcon comprises:

[0129] EVcon=Econ+Vcon;

[0130] The value of the feedback adaptive adjustment coefficient Kf obtained based on the fifth intermediate variable value EVcon, the speed adjustment coefficient, the error adjustment coefficient, the bias coefficient, the first intermediate variable value Etemp and the second intermediate variable value Vtemp includes:

[0131] If EVcon=11, then Kf=a11*Vtemp+b11*Etemp+c11;

[0132] If EVcon=12, then Kf=a12*Vtemp+b12*Etemp+c12;

[0133] If EVcon=13, then Kf=a13*Vtemp+b13*Etemp+c13;

[0134] If EVcon=21, then Kf=a21*Vtemp+b21*Etemp+c21;

[0135] If EVcon=22, then Kf=a22*Vtemp+b22*Etemp+c22;

[0136] If EVcon=23, then Kf=a23*Vtemp+b23*Etemp+c23;

[0137] If EVcon=31, then Kf=a31*Vtemp+b31*Etemp+c31;

[0138] If EVcon=32, then Kf=a32*Vtemp+b32*Etemp+c32;

[0139] If EVcon=33, then Kf=a33*Vtemp+b33*Etemp+c33, that is, the feedback adaptive adjustment coefficient value is determined based on the value of Evcon and then the value of the control quantity is calculated. The calculation method of the feedback adaptive adjustment coefficient provided by the present invention can further improve the accuracy of the output control quantity, so as to obtain more accurate displacement feedback information of the servo motor to be tested.

[0140] For the motor driver, it receives power from the power supply port, converts the PWM control quantity output by the digital processor into a power output signal, outputs it to the motor through the welding-free wiring port, and drives the motor to rotate.

[0141] For the input module, it is used to input the test function corresponding to the test program, including:

[0142] The test function of the step test is:

[0143]

[0144] Among them, A1 is the amplitude, T1 is the step time, T2 is the return to zero time, and y1(t1) is the target displacement position at time t1.

[0145] The test function of the running-in test is:

[0146]

[0147] Among them, A2 is the amplitude, N is the period, f2 is the frequency, t2 is the time required for f2 to execute one cycle, and y2(t2) is the target displacement position at time t2.

[0148] The test function of the small instruction sweep frequency test is:

[0149]

[0150] Where A3 is the amplitude, f3 is the frequency, f3 = 1, 2, ..., N, N is the maximum frequency allowed by the servo, t3 is the time required for f3 to execute a cycle, T n is the sum of the time it takes for the frequency f3 to be executed from 1 to N, and y3(t3) is the target displacement position at time t3.

[0151] The parameter values ​​of each test function can be set according to the test requirements to meet the test tasks of different types of steering gears, thereby forming a customized test system for steering gear assembly testing.

[0152] For the display module, when the test mode is a step test, the digital processor calculates the average value of the displacement feedback information after the step is maintained for a certain period of time. If the absolute value of the deviation between the average value and the amplitude A1 is less than the first preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms.

[0153] The absolute value Adv of the deviation between the average value and the amplitude A1 is:

[0154] Adv=|MaxAmplitude-StepStableValue|,

[0155] Among them, MaxAmplitude is the maximum mechanical stroke of the servo to be tested, and StepStableValue is the average value of the displacement feedback information.

[0156] Exemplarily, the average value of the displacement sensor for 0.5 seconds after the step is maintained may be calculated; and the first preset threshold may be set to 0.5.

[0157] The step holding time and the first preset threshold value can be set according to the type of the servo to be tested and the actual test requirements. The present invention does not make any specific limitation here, as long as it can meet the experimental requirements.

[0158] When the test mode is a running-in test, the digital processor calculates the integral of the absolute value of the error between the displacement feedback information of a certain number of cycles and the test function y2(t2). When it is less than a second preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms.

[0159] The integral Iaev of the absolute value of the error between the displacement feedback information and the test function y2(t2) is:

[0160]

[0161] Wherein, dfi is the displacement feedback information of a certain number of cycles.

[0162] Exemplarily, displacement feedback information of 10 cycles may be calculated; and the second preset threshold may be set to 5.

[0163] The number of cycles and the second preset threshold value can be set according to the type of the servo to be tested and the actual test requirements. The present invention does not make any specific limitation here, as long as it can meet the experimental requirements.

[0164] When the test mode is a small instruction sweep test, the digital processor obtains T n The maximum value of the internal displacement feedback information is used to calculate the tracking amplitude based on the maximum value. When the tracking amplitude is less than the third preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms; wherein, the tracking amplitude Mtemp is:

[0165]

[0166] Among them, SineSweepMaxAmpvalue is the maximum value of the displacement feedback information, and MinAmplitude is the minimum required value of the insensitive area of ​​the servo.

[0167] Exemplarily, the third preset threshold may be set to 2.

[0168] The third preset threshold value can be set according to the type of the servo to be tested and the actual test requirements. The present invention does not make any specific limitation here, and it can be based on what can meet the experimental requirements.

[0169] Preferably, the display module may also include an LED display screen for displaying the absolute value of the deviation between the average value of the displacement feedback information and the amplitude A1, the integral of the absolute value of the error between the displacement feedback information and the test function y2(t2), and the numerical value of the tracking amplitude; and setting the duration of the buzzer alarm to 10s.

[0170] Exemplarily, the working mode of the steering gear assembly test system proposed by the present invention is as follows:

[0171] For the servo to be tested, connect the motor and displacement sensor of the servo to be tested through the welding-free wiring port, then select the step test mode through the test mode selection module, and press the button switch once to start the test, wait for the test to end, record the test results, and judge whether the current test result is qualified. If qualified, the green LED light of the control display module is always on, otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms, indicating that the transmission mechanism of the current servo to be tested is stuck and the transmission mechanism of the current servo to be tested needs to be replaced. After replacing the transmission mechanism, perform the step test again until the test result is qualified and enter the running-in test. Select the running-in test mode through the test mode selection module, press the button switch once to start the test, wait for the test to end, record the test results, then select the small-angle sweep test mode through the test mode selection module, press the button switch once to start the test, record the test results, and judge whether the two test results are qualified. If qualified, the green LED light of the control display module is always on, otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms, indicating that the assembly preload of the transmission mechanism is not appropriate and the gasket needs to be adjusted. Specifically, when the running-in test fails, reduce the gasket to reduce the preload; when the small-angle sweep test fails, add the gasket to increase the preload. After the adjustment operation is completed, enter the step test again until the test results of the running-in test mode and the small-angle sweep test mode are qualified, and the servo product after the assembly test is formally assembled to the servo product to debug and test the performance of the whole product.

[0172] Specifically, for the step test, if a new transmission mechanism is replaced, the relationship between the transmission friction coefficient of the new transmission mechanism and the transmission friction coefficient of the current servo transmission mechanism is:

[0173] objectFriction=NowFriction*|StepStable Value / MaxAmplitude|, where objectFriction is the transmission friction parameter of the new transmission mechanism, NowFriction is the transmission friction coefficient of the transmission mechanism of the current servo, StepStableValue is the average value of the displacement feedback information of the servo during the step test, and MaxAmplitude is the maximum mechanical stroke of the product corresponding to the servo.

[0174] For the running-in test, the pad thickness is reduced, and the reduction in pad thickness PadThicknessl is:

[0175]

[0176] Among them, RunningErrorIntergration is the integral of the absolute value of the error, For small instruction sweep frequency test, the thickness of the pad is increased, and the increase in the pad thickness PadThickness2 is:

[0177]

[0178] Among them, SineSweepMaxAmpvalue is the maximum value of the tracking amplitude, and MinAmplitude is the minimum required value of the insensitive area of ​​the servo.

[0179] Based on the steering gear assembly and testing system provided by the present invention, debugging can be achieved while assembling. If the steering gear in the previous assembly link does not meet the test requirements, it will be reworked immediately and transferred to the next link after passing the test. This achieves quality control in the production link, reduces the amount of rework, improves production efficiency, facilitates mass production of products, leaves sufficient stable margin for whole machine performance debugging, and improves product reliability.

[0180] Those skilled in the art will appreciate that all or part of the processes of the above-mentioned embodiments can be implemented by instructing related hardware through a computer program, and the program can be stored in a computer-readable storage medium, wherein the computer-readable storage medium is a disk, an optical disk, a read-only storage memory, or a random access memory, etc.

[0181] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by any technician familiar with the technical field within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention.

Claims

1. A high-efficiency steering gear assembly test system, characterized in that: The system comprises: The welding-free wiring module is used to connect the displacement sensor and the motor of the mechanically assembled servo, receive the displacement feedback information output by the displacement sensor, and output a driving signal to the motor; A test mode selection module, used to select a test mode of the servo, wherein the test modes include a step test, a running-in test, and a small command sweep test; A digital processor performs closed-loop control of the motor according to the test function corresponding to the test mode and the displacement feedback information, and outputs the generated control quantity to the motor driver; The motor driver generates a drive signal based on the control quantity output by the digital processor and transmits it to the motor through a solder-free wiring module.

2. A high-efficiency steering gear assembly test system according to claim 1, characterized in that: The system further comprises an input module connected to the digital processor and configured to input a test function corresponding to the test mode; The test function of the step test is: Among them, A1 is the amplitude, T1 is the step time, T2 is the zero return time, and y1(t1) is the target displacement position at time t1; The test function of the running-in test is: Where A2 is the amplitude, N is the period, f2 is the frequency, t2 is the time required for f2 to execute one cycle, and y2(t2) is the target displacement position at time t2; The test function of the small instruction sweep frequency test is: Wherein, A3 is the amplitude, f3 is the frequency, f3=1, 2, ..., N, N is the maximum frequency allowed by the servo, t3 is the time required for f3 to execute a cycle, T n is the sum of the time it takes for the frequency f3 to be executed from 1 to N, and y3(t3) is the target displacement position at time t3.

3. A high-efficiency steering gear assembly test system according to claim 2, characterized in that: The system further comprises a display module, which is connected to the digital processor and comprises a plurality of LED lights and a buzzer for displaying the test results; When the test mode is a step test, the digital processor calculates the average value of the displacement feedback information after the step is maintained for a certain period of time. If the absolute value of the deviation between the average value and the amplitude A1 is less than the first preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms; When the test mode is a running-in test, the digital processor calculates the integral of the absolute value of the error between the displacement feedback information of a certain number of cycles and the test function y2(t2). When it is less than a second preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms; When the test mode is a small instruction sweep test, the digital processor obtains the maximum value of the displacement feedback information in Tn, and calculates the tracking amplitude based on the maximum value. When the tracking amplitude is less than the third preset threshold, it indicates that the test result is qualified, and the green LED light in the display module is always on. Otherwise, it indicates that the test result is abnormal, the red LED light is always on and the buzzer alarms; wherein, the tracking amplitude Mtemp is: Among them, SineSweepMaxAmpvalue is the maximum value of the displacement feedback information, and MinAmplitude is the minimum required value of the insensitive area of ​​the servo.

4. A high-efficiency steering gear assembly test system according to claim 3, characterized in that: The control quantity output3 is generated in the following manner: outPut1=Kv*(Kp*(Ref-Fed)-Kf*Fed′+Ref′)-Fed″+Ref″, outPut3 = LimitDesign(LF(s) * outPut2), where output1 and output2 are intermediate variables, Fed is displacement feedback information, Kv is the differential control coefficient, Kp is the displacement control coefficient, Kf is the feedback adaptive adjustment coefficient, Fed' is the differential of Fed, Ref' is the differential of Ref, Fed'' is the second differential of Fed, Ref'' is the second differential of Ref, Ka is the torque control coefficient, Ki is the integral control coefficient, Ref is the target displacement position output by the test function in the current execution cycle, MaxDesignSpeed is the maximum operating speed of the servo; fun() is a function, when the function input is greater than 2, the function output is equal to 2, when the function input is less than 0.5, the function output is equal to 0.5, in other cases, the function output is equal to the input; LimitDesign() is a limiter function, when the input is less than -0.99, the output is equal to -0.99, when the input is greater than 0.99, the output is equal to 0.99, in other cases, the function output is equal to the input; LF(s) is the transfer function of the low-pass filter, and its calculation method is as follows, s is the complex variable of the Laplace transform.

5. A high-efficiency steering gear assembly and testing system according to claim 4, characterized in that: The differential control coefficient Kv, the displacement control coefficient Kp, the torque control coefficient Ka, and the integral control coefficient Ki are determined based on the trial-and-error method or the simulation method.

6. A high-efficiency steering gear assembly and testing system according to claim 4, characterized in that: For each control cycle, the feedback adaptive adjustment coefficient Kf is determined in the following manner: A1: Calculate the tracking error E and the tracking speed V based on the target displacement position and the displacement feedback information; A2: Construct a tracking error segment based on the maximum mechanical stroke of the servo and a tracking speed segment based on the maximum operating speed. Specifically: The tracking error segment includes E1 - E2, E2 - E3, E3 - E4, and the tracking speed segment includes V1 - V2, V1 - V2, V3 - V4, where 0 < E1 < E2 < E3 < E4 < 2Emax, 0 < V1 < V2 < V3 < V4 < Vmax. After determining E1 and E4, E2 and E3 are equally divided based on E1 and E4. After determining V1 and V4, V2 and V3 are equally divided based on V1 and V4. Emax is the maximum mechanical stroke of the servo, and Vmax is the maximum operating speed; Construct the segmented adjustment coefficients P1, P2, and P3, where 0 < P1, P2, P3 < 1; A3: Calculate the speed adjustment coefficient, the error adjustment coefficient, and the bias coefficient based on the tracking error segment, the tracking speed segment, and the segmented adjustment coefficients; A4: Calculate the first intermediate variable value Etemp based on the relationship between the tracking error E and the error range endpoint values E1 and E4, and calculate the second intermediate variable value Vtemp based on the relationship between the tracking speed V and the speed range endpoint values V1 and V4; A5: Calculate the third intermediate variable value Econ based on the relationship between the first intermediate variable value Etemp and the intermediate values ​​E2 and E3 of the error range, and calculate the fourth intermediate variable value Vcon based on the relationship between the second intermediate variable value Vtemp and the intermediate values ​​V2 and V3 of the speed range; A6: The fifth intermediate variable value EVcon ​​is calculated based on the third intermediate variable value Econ and the fourth intermediate variable value Vcon, and the value of the feedback adaptive adjustment coefficient Kf is obtained based on the fifth intermediate variable value EVcon, the speed adjustment coefficient, the error adjustment coefficient, the bias coefficient, the first intermediate variable value Etemp and the second intermediate variable value Vtemp.

7. A high-efficiency steering gear assembly and testing system according to claim 6, characterized in that: The calculating of the speed adjustment coefficient, the error adjustment coefficient and the bias coefficient based on the tracked error segment and the tracked speed segment comprises: The speed adjustment coefficients are a11, a12, a13, a21, a22, a23, a31, a32, a33, and the specific calculation method is: The error adjustment coefficients are b11, b12, b13, b21, b22, b23, b31, b32, b33, and are specifically calculated as follows: The bias coefficients are c11, c12, c13, c21, c22, c23, c31, c32, c33, and are specifically calculated as follows: c11=1-a11*V1-b11*E1, c12=1+P1-a12*V2-b12*E1, c13=1+P1-P2-a13*V3-b13*E1, c21=1-P1-a21*V1-b21*E2, c22=1-a22*V2-b22*E2, c23=1+P1-a23*V3-b23*E2, c21=1-P1-P2-a31*V1-b21*E3, c32=1-P1-a32*V2-b32*E3, c33=1-a33*V3-b33*E3.

8. A high-efficiency steering gear assembly and testing system according to claim 6, characterized in that: The calculation of the first intermediate variable value Etemp based on the relationship between the tracking error E and the error range endpoint values ​​E1 and E4, and the calculation of the second intermediate variable value Vtemp based on the relationship between the tracking speed V and the speed range endpoint values ​​V1 and V4 include: If the tracking error E is less than E1 or greater than the negative of E1, then Etemp = E1; if the tracking error E is greater than E4 or less than the negative of E4, then Etemp = E4; otherwise, Etemp = |E|, where || is the absolute value; If the tracking speed V is less than V1 or greater than the negative of V1, then Vtemp=V1; if the tracking error V is greater than V4 or less than the negative of V4, then Vtemp=V4; otherwise, Vtemp=|V|.

9. The high-efficiency steering gear assembly and testing system according to claim 6, characterized in that: The method of calculating the third intermediate variable value Econ based on the relationship between the first intermediate variable value Etemp and the intermediate values ​​E2 and E3 of the error range, and calculating the fourth intermediate variable value Vcon based on the relationship between the second intermediate variable value Vtemp and the intermediate values ​​V2 and V3 of the speed range comprises: If Etemp is greater than E3, then Econ = 30, if Etemp is greater than E2, then Econ = 20, otherwise, Econ = 10; If Vtemp is greater than V3, then Vcon=3; if Vtemp is greater than E2, then Vcon=2; otherwise, Vcon=1.

10. The high-efficiency steering gear assembly and testing system according to claim 6, characterized in that: The calculation of the fifth intermediate variable value EVcon ​​based on the third intermediate variable value Econ and the fourth intermediate variable value Vcon comprises: EVcon=Econ+Vcon; The value of the feedback adaptive adjustment coefficient Kf obtained based on the fifth intermediate variable value EVcon, the speed adjustment coefficient, the error adjustment coefficient, the bias coefficient, the first intermediate variable value Etemp and the second intermediate variable value Vtemp includes: If EVcon=11, then Kf=a11*Vtemp+b11*Etemp+c11; If EVcon=12, then Kf=a12*Vtemp+b12*Etemp+c12; If EVcon=13, then Kf=a13*Vtemp+b13*Etemp+c13; If EVcon=21, then Kf=a21*Vtemp+b21*Etemp+c21; If EVcon=22, then Kf=a22*Vtemp+b22*Etemp+c22; If EVcon=23, then Kf=a23*Vtemp+b23*Etemp+C23; If EVcon=31, then Kf=a31*Vtemp+b31*Etemp+c31; If EVcon=32, then Kf=a32*Vtemp+b32*Etemp+c32; If EVcon=33, then Kf=a33*Vtemp+b33*Etemp+c33.

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