Intelligent test system for detecting performance of DCT actuator DC brush motor
By designing intelligent testing systems that integrate PLC control modules, brushed motor drive modules, etc., the problem of difficulty in accurately testing the performance of DC brushed motors of the DCT actuator in the prior art is solved, and high-precision detection and quality control of the motor performance of the DCT actuator is achieved.
Patent Information
- Application Number
- CN202510155986.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-12
- Publication Date
- 2025-05-30
AI Technical Summary
The prior art is difficult to accurately test the performance of the DC brushed motor of the DCT actuator, especially in linear motion and stability detection under load conditions.
An intelligent test system was designed, integrating PLC control module, brushed motor drive module, man-machine exchange module, laser displacement sensor module and test platform. The analog voltage signal was output through the PLC control module, and the brushed motor was controlled to move linearly under a 5kg load, and real-time feedback and dynamic observation were achieved through programmable Hall sensors and laser displacement sensors.
It realizes accurate testing of the performance of DCT actuator motors, ensures consistency between motor response and set instructions, and provides a reliable solution for the quality inspection of DCT actuator motors, with the advantages of high precision, simple structure and convenient operation.
Smart Images
Figure CN120064969A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of automotive testing, and more particularly to an intelligent testing system for detecting the performance of a DC brushed motor of a DCT actuator. Background Art
[0002] With the rapid development of the automotive industry, DCT transmissions have been widely used in various vehicle models due to their advantages such as rapid gear shifting and low power loss. As a key component in the transmission, the performance of the DCT actuator directly affects the overall performance of the transmission. Therefore, it is particularly important to accurately test the DCT actuator.
[0003] In summary, the present invention designs an efficient and accurate testing device for evaluating the performance of the shift motor of a dual-clutch transmission (DCT) actuator. Summary of the Invention
[0004] Aiming at the deficiencies in the prior art, the purpose of the present invention is to provide an intelligent testing system for detecting the performance of a DC brushed motor of a DCT actuator, which integrates a PLC, a motor drive, and a touch-screen human-machine interface system, accurately controls the linear movement of the brushed motor under a 5 kg load condition, and realizes instant feedback by reading the voltage value of the programmable Hall sensor built into the motor, dynamically observes whether the operation of the DCT actuator motor is stable and reliable, ensures the consistency between the motor response and the set command, and provides a reliable solution for the quality detection of the DCT actuator motor.
[0005] To achieve the above object, the present invention is implemented by the following technical solutions: An intelligent testing system for detecting the performance of a DC brushed motor of a DCT actuator includes a PLC control module, a brushed motor drive module, a human-machine interaction module, a laser displacement sensor module, and a test platform; the test platform is used to install the DCT actuator, the DCT actuator is connected to the brushed motor drive module, the PLC control module is connected to the brushed motor drive module, the laser displacement sensor module is connected to the PLC control module, and the PLC control module is also connected to the human-machine interaction module.
[0006] Preferably, the PLC control module is used to control the action of the test platform fixture, linearly and steadily output an analog voltage of 0 - 4.4V within a predetermined time, and this voltage signal controls the rotation of the brushed motor through the brushed motor drive module. The PLC control module simultaneously receives the feedback voltage signal from the Hall sensor and the laser displacement sensor signal, compares the measurement data result with the theoretical data, and makes a judgment on the final test result.
[0007] Preferably, the brushed motor drive module receives an analog voltage signal from the PLC control module, converts it into a motor drive signal, and drives the brushed motor to rotate. At the same time, this module receives the feedback voltage signal from the Hall sensor inside the brushed motor, compares it with the given voltage signal, calculates the control error, and adjusts the drive signal accordingly to achieve precise control of the brushed motor.
[0008] Preferably, the human-machine interaction module uses virtual switch buttons to display the analog voltage value, the feedback voltage value of the Hall sensor, and the voltage curve graph in real time, and displays and records the test results in an excel spreadsheet file.
[0009] Preferably, the laser displacement sensor module introduces a high-precision laser displacement sensor, converts the real-time detected distance into a 4-20 mA current signal, and transmits it to the PLC control module. The PLC control module converts the current signal into a millimeter value through internal instructions, real-time monitors and feedbacks the real-time position of the motor and the actuator driven by it, compares it with the theoretical position, further verifies the stroke control accuracy of the DCT actuator, and ensures the accuracy of the stroke range during the dynamic test process.
[0010] Advantages of the present invention: By combining the PLC, the human-machine interface, the laser displacement sensor and the brushed motor drive, the present invention realizes the precise test of the performance of the DCT actuator. Using the programmable Hall sensor for position feedback, the running state of the DCT actuator can be monitored in real time, and the control parameters can be adjusted as needed. In addition, the present invention also has the advantages of simple structure, convenient operation and high test accuracy. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will be described in detail below in conjunction with the drawings and specific embodiments;
[0012] Figure 1 is the electrical schematic diagram of the present invention;
[0013] Figure 2 is the test schematic diagram of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0014] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the present invention will be further described below in conjunction with specific embodiments.
[0015] Refer to Figure 1-2, this specific implementation adopts the following technical solutions: An intelligent test system for detecting the performance of a DC brushed motor of a DCT actuator, including a PLC control module 1, a brushed motor drive module 2, a human-machine interaction module 3, a laser displacement sensor module 4, and a test platform 5; the test platform 5 is used to install the DCT actuator, the DCT actuator is connected to the brushed motor drive module 2, the PLC control module 1 is connected to the brushed motor drive module 2, the laser displacement sensor module 4 is connected to the PLC control module 1, and the PLC control module 1 is also connected to the human-machine interaction module 3.
[0016] It should be noted that the PLC control module 1 is used to control the movement of the test platform fixture, linearly and steadily output an analog voltage of 0 - 4.4V within a predetermined time, and this voltage signal controls the rotation of the brushed motor M through the brushed motor drive module. The PLC control module 1 simultaneously receives the feedback voltage signal from the Hall sensor and the laser displacement sensor signal, compares the measured data results with the theoretical data, and makes a judgment on the final test result.
[0017] It should be noted that the brushed motor drive module 2 receives the analog voltage signal from the PLC control module 1, converts it into a motor drive signal, and drives the brushed motor to rotate. At the same time, this module receives the feedback voltage signal from the Hall sensor inside the brushed motor, compares it with the given voltage signal, calculates the control error, and adjusts the drive signal accordingly to achieve precise control of the brushed motor.
[0018] It should be noted that the human-machine interaction module 3 adopts virtual switch buttons, and real-time displays the analog voltage value, the feedback voltage value of the Hall sensor, the voltage curve graph, and displays and records the test results into an excel spreadsheet file.
[0019] It should be noted that the laser displacement sensor module 4 introduces a high-precision laser displacement sensor, converts the real-time detected distance into a 4 - 20mA current signal, transmits it to the PLC control module 1, and the PLC control module 1 converts the current signal into a millimeter value through internal instructions, real-time monitors and feeds back the real-time position of the motor and the actuator it drives, compares it with the theoretical position, further verifies the stroke control accuracy of the DCT actuator, and ensures the accuracy of the stroke range during the dynamic test process.
[0020] In addition, the test platform 5 is used to fix the DCT actuator and provide a load simulation situation.
[0021] The test method of this specific embodiment is as follows: First, install the DCT actuator on the test platform and connect the brushed motor drive module to the DCT actuator. Then, output an analog voltage signal through the PLC control module to control the brushed motor drive module to control the motor to move linearly under a 5 kg load. During the test, the programmable Hall sensor will detect the position of the brushed motor in real time and feedback the detected information to the brushed motor drive module and the PLC control module. By comparing the given voltage signal and the feedback voltage signal, as well as the displacement and stroke measured by the laser displacement sensor, it can be determined whether the DCT actuator has reached the expected position and speed. If the feedback voltage fails to reach the given analog voltage value, it indicates that the motor cannot reach the expected position within the predetermined time, and thus it is determined that the performance of the DCT actuator is poor.
[0022] Through the integration of modern control technology and user-friendly interactive design, the present invention constructs a set of efficient and precise DCT actuator dynamic performance test system, filling the demand gap for such high-precision test equipment in the market, and providing strong support for the quality control and technological innovation of the automotive transmission manufacturing industry.
[0023] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. The above embodiments and the descriptions in the specification only illustrate the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.
Claims
1. An intelligent test system for detecting the performance of a DC brushless motor of a DCT actuator, characterized in that: The invention comprises a PLC control module (1), a brush motor drive module (2), a human-machine exchange module (3), a laser displacement sensor module (4) and a test platform (5); the test platform (5) is used to install a DCT actuator, the DCT actuator is connected to the brush motor drive module (2), the PLC control module (1) is connected to the brush motor drive module (2), the laser displacement sensor module (4) is connected to the PLC control module (1), and the PLC control module (1) is also connected to the human-machine exchange module (3).
2. The intelligent test system for detecting the performance of a brushless DC motor of a DCT actuator according to claim 1, characterized in that: The PLC control module (1) is used to control the movement of the test platform fixture, and linearly and steadily outputs a 0-4.4V analog voltage within a predetermined time. The voltage signal controls the rotation of the brushed motor through the brushed motor drive module. The PLC control module (1) simultaneously receives the feedback voltage signal from the Hall sensor and the laser displacement sensor signal, and makes a judgment on the final test result by comparing the measured data result with the theoretical data.
3. The intelligent test system for detecting the performance of a brushless DC motor of a DCT actuator according to claim 1, characterized in that: The brushed motor drive module (2) receives the analog voltage signal from the PLC control module (1) and converts it into a motor drive signal to drive the brushed motor to rotate; at the same time, the brushed motor drive module (2) receives the feedback voltage signal from the Hall sensor inside the brushed motor, compares it with the given voltage signal, calculates the control error, and adjusts the drive signal accordingly to achieve precise control of the brushed motor.
4. The intelligent test system for detecting the performance of a brushless DC motor of a DCT actuator according to claim 1, characterized in that: The human-machine exchange module (3) uses a virtual switch button to display the analog voltage value, the Hall sensor feedback voltage value, and the voltage curve in real time, and displays and records the test results in an Excel spreadsheet file.
5. The intelligent test system for detecting the performance of a brushless DC motor of a DCT actuator according to claim 1, characterized in that: The laser displacement sensor module (4) introduces a high-precision laser displacement sensor, converts the real-time detected distance into a 4-20 mA current signal, and transmits it to the PLC control module (1). The PLC control module (1) converts the current signal into a millimeter value through internal command conversion, monitors and feeds back the real-time position of the motor and the actuator driven by it in real time, compares it with the theoretical position, and further verifies the stroke control accuracy of the DCT actuator, ensuring the accuracy of the stroke range during the dynamic test process.