Gear case running-in sample device and method capable of rapidly positioning and clamping

Abstract

The invention discloses a gear box running-in sample device and method capable of rapidly positioning and clamping, and belongs to the technical field of gear box testing equipment. Comprising a rack, a rapid positioning and clamping device, a driving assembly and a control assembly, the rapid positioning and clamping device, the driving assembly and the control assembly are fixed to the rack, the rapid positioning and clamping device achieves sample pre-positioning through an adaptive positioning groove in the top face of a positioning base, and two-way gapless clamping is formed in cooperation with a downward pressing fixing air cylinder of an upward pressing assembly and an air cylinder propelling device of a side ejecting assembly; the driving assembly receives an operation panel rotating speed instruction through the frequency converter and controls a motor output shaft to drive a to-be-run-in gearbox to operate. The control assembly integrates a temperature sensor and a torque sensor, motor temperature and gearbox torque data are collected and analyzed in real time through a data collection module and a data processing unit, and the result is visually presented through a display screen. Through a cooperation mechanism of rapid positioning, precise driving and real-time monitoring, efficient and stable running-in of the sample is achieved, and the device is suitable for running-in test scenes of mechanical parts such as a gearbox.

Description

Technical Field

[0001] The present invention relates to the technical field of gear box testing equipment, and in particular to a gear box running-in sample device and method for rapid positioning and clamping. Background Art

[0002] In the production and manufacturing of gearboxes, newly assembled gearboxes need to undergo running-in tests to verify the fitting accuracy of internal parts (such as drive shafts, bearings, worm gears, etc.) and whether the parts processing dimensions meet the usage requirements under actual working conditions. Existing equipment mainly relies on manual observation or post-testing to monitor the running-in process. It lacks the real-time collection and analysis function of key parameters such as temperature and torque, and is unable to detect part assembly deviations or abnormal wear problems in a timely manner, resulting in insufficient accuracy and reliability of test data.

[0003] A Chinese patent application, CN102620936B, discloses a bearing running-in test device. The device comprises an operating cabinet, a running-in test bench, and a core sleeve assembly and disassembly platform, which are sequentially connected in series via hydraulic oil pipes. The running-in test bench comprises a housing, a spindle, a pulley, a gearbox, a clamping cylinder, a V-seat, a stop pin, a set nut, a loosening nut, a clamping device, a core sleeve, and an electromagnetic speed-regulating motor. The core sleeve assembly and disassembly platform comprises a hydraulic cylinder, a pressure head, a support, and a bed. The device drives the running-in rolling bearing at a certain speed while applying a certain radial load to the rolling bearing, running it in for a certain period of time to remove fine burrs and shallow marks, eliminate adverse effects, and thus eliminate potential accidents. The device is driven by a hydraulic cylinder for compression and relies on manual or semi-manual adjustment of mechanical components such as the stop pin and nut. The clamping process involves multiple steps, resulting in low positioning efficiency and inability to meet the requirements for rapid positioning. Therefore, it is urgent for those skilled in the art to solve the above technical problems. Summary of the Invention

[0004] The present invention aims to solve the above-mentioned prior art, improve the positioning efficiency of the gearbox to be run-in, and improve the reliability of the test results of the internal components of the gearbox.

[0005] The technical solutions adopted in the present invention are:

[0006] A gearbox running-in sample device with rapid positioning and clamping is used for sample testing of internal parts of the gearbox. The rapid positioning and clamping device is installed on a frame and clamps the gearbox to be tested. The driving component drives the internal parts of the gearbox to operate. The operating parameters of the internal parts of the gearbox are adjusted through the control component and the operating parameters are displayed on the display screen.

[0007] Furthermore, it includes a frame, a quick positioning and clamping device, a drive assembly and a control assembly;

[0008] The quick positioning and clamping device, the driving assembly and the control assembly are all fixedly mounted on the frame;

[0009] The rapid positioning and clamping device includes a positioning base and a clamping mechanism, wherein the positioning base is fixedly mounted on the top of the frame, and a positioning groove is provided on the top surface of the positioning base; the clamping mechanism includes an upper pressing assembly and a side top assembly, wherein the upper pressing assembly is fixedly mounted above the positioning base through a mounting bracket, and the side top assembly is fixedly mounted on the side of the positioning base through a mounting base;

[0010] The drive assembly includes a motor and a frequency converter. The motor is fixedly mounted on one side of the frame, and its output shaft is coaxially connected to the input shaft of the gearbox through a coupling. The frequency converter is fixedly mounted in the electrical control cabinet of the frame and is electrically connected to the motor through a wire.

[0011] The control component includes a temperature sensor, a torque sensor, a data acquisition module and a data processing unit; the temperature sensor and torque sensor are respectively fixed to the motor through threaded connections or clamps; the data acquisition module is fixedly installed on the frame, the signal input end of the data acquisition module is electrically connected to the temperature sensor and torque sensor respectively through wires, and the signal output end of the data acquisition module is electrically connected to the data processing unit through wires; the data processing unit is fixedly installed in the electrical control cabinet of the frame.

[0012] By adopting this technical solution, the rack serves as the core load-bearing structure, integrating and securing the rapid positioning and clamping device, drive components, and control components into a compact, integrated device. Physically connecting the racks enables spatial coordination among the functional modules, eliminating the operational inconveniences associated with a dispersed layout while ensuring precise linkage between components, providing a structural foundation for efficient gearbox run-in testing.

[0013] Furthermore, the upper pressure assembly includes a downward pressure fixing cylinder, the cylinder body of the downward pressure fixing cylinder is fixedly connected to the frame through the mounting bracket, and the piston rod of the downward pressure fixing cylinder extends vertically downward to above the positioning groove;

[0014] The side top assembly includes a cylinder propulsion device and a propulsion fixture. The cylinder body of the cylinder propulsion device is fixedly connected to the frame through a mounting seat. The propulsion fixture is fixedly connected to the piston rod of the cylinder propulsion device and extends horizontally toward the positioning groove.

[0015] By adopting the above technical solution, the downward pressure fixing cylinder of the upper pressure assembly is fixed to the top of the positioning base through the mounting bracket, and the cylinder propulsion device of the side top assembly is fixed to the side of the positioning base through the mounting base for vertical and horizontal bidirectional assembly. This linkage design of the upper and lower and side cylinders enables the gear box specimen to be initially aligned through the positioning groove during clamping, and to be fixed without gaps through the rapid advancement of the cylinder piston rod, which significantly shortens the clamping time. At the same time, the multi-directional clamping force distribution improves the stability of the specimen and avoids test errors caused by displacement during the running-in process.

[0016] Furthermore, air pressure regulating valves are installed at the air source interfaces of the downward-pressing fixing cylinder and the cylinder propulsion device, and the air pressure regulating valves are connected to an external air source through pipelines.

[0017] By adopting this technical solution, the air pressure regulating valve is directly installed at the air source interface of the downward-pressing fixed cylinder and the cylinder propulsion device. Connected to the external air source via piping, this assembly integrates the clamping force adjustment function with the cylinder body. Operators can control the cylinder's output pressure in real time by adjusting the air pressure regulating valve. This not only adapts to the clamping requirements of gearboxes of different sizes and materials, but also avoids the tedious disassembly and adjustment steps required for traditional mechanical clamps, further improving the flexibility and efficiency of the clamping process.

[0018] Furthermore, the control circuit of the frequency converter extends to the operation panel of the electrical control cabinet, and the operation panel is provided with a speed parameter input interface.

[0019] By adopting this technical solution, the inverter's control circuitry extends to the electrical control cabinet's operating panel, and a speed parameter input interface is provided on the panel, enabling direct connectivity with the drive components. Operators can adjust inverter parameters in real time through panel input, thereby controlling motor speed, without having to enter the electrical control cabinet for debugging. This significantly improves the efficiency of switching between different operating conditions (such as low-speed running-in and high-speed testing), meeting diverse testing needs.

[0020] Furthermore, the signal output end of the data processing unit is electrically connected to the display screen of the rack, and the display screen is fixedly mounted on the front panel of the rack.

[0021] By adopting this technical solution, the data processing unit is electrically connected to the display screen on the front panel of the frame via its signal output terminal, integrating the collection, processing, and visualization of monitoring data such as temperature and torque. Real-time monitoring data, processed by the data acquisition module and the data processing unit, is presented directly on the display screen. Operators can visually observe parameter changes during the running-in process without the need for additional equipment, facilitating the timely detection of anomalies such as sudden temperature rises and torque fluctuations, allowing for intervention. This effectively improves the reliability of test data and the accuracy of the assessment of the condition of the gearbox's internal components.

[0022] Furthermore, the positioning groove is adapted to the gear box to be run-in, and the inner surface of the positioning groove of the positioning base is provided with anti-slip grooves, and the anti-slip grooves are in contact with the bottom surface of the gear box to be run-in.

[0023] By adopting the above technical solution, the design of the positioning groove is adapted to the gearbox to be run-in, combined with the contact cooperation between the anti-slip pattern on the inner surface of the positioning groove and the bottom surface of the gearbox. When the gearbox specimen is placed, the contour of the positioning groove can quickly guide it into the correct position, reducing manual alignment time. The anti-slip pattern prevents the specimen from sliding and deflecting due to external forces before clamping by increasing contact friction, further shortening the clamping preparation time. At the same time, it provides a stable initial positioning foundation for the subsequent precise clamping of the upper pressure and side top components.

[0024] The present invention further discloses a gearbox sample running-in method with rapid positioning and clamping, which uses a gearbox sample running-in device with rapid positioning and clamping to detect the internal structure of the gearbox, including the following steps:

[0025] S1. Sample positioning and clamping: Secure the gearbox to be run-in in the positioning slot of the quick positioning and clamping device, and clamp it together using the upper pressure assembly and the side lift assembly;

[0026] S2. Drive run-in operation: The drive assembly drives the gearbox to be run-in at the set speed to complete the run-in process;

[0027] S3. Real-time parameter monitoring and adjustment: The control components collect and analyze the temperature and torque parameters during the running-in process, and adjust the operating status based on the monitoring results.

[0028] Furthermore, the step S1 specifically includes:

[0029] Place the gearbox to be run-in into the positioning groove of the positioning base, so that the bottom surface of the gearbox contacts and fits with the anti-slip grooves on the inner surface of the positioning groove;

[0030] Start the downward fixing cylinder of the upward pressure assembly, and the piston rod extends vertically downward to the top of the positioning groove and presses the top of the gear box;

[0031] Synchronously start the cylinder propulsion device of the side push assembly, and the piston rod pushes the tooling fixture to extend horizontally toward the positioning groove and press against the side of the gear box;

[0032] The air pressure regulating valve is used to adjust the air source pressure of the downward fixing cylinder and the cylinder propulsion device so that the clamping force meets the specimen clamping requirements.

[0033] Furthermore, the step S2 specifically includes:

[0034] Input the target speed through the speed parameter input interface of the control component;

[0035] The inverter adjusts the power supply frequency and voltage parameters of the motor after receiving the speed command;

[0036] The motor output shaft is coaxially connected to the input shaft of the gearbox to be run-in through a coupling, driving the internal components of the gearbox to continuously operate at the set speed to complete the sample running-in process.

[0037] Furthermore, the step S3 specifically includes:

[0038] The temperature sensor collects the motor operating temperature data in real time, and the torque sensor collects the torque data of the input shaft of the gearbox to be run-in in real time;

[0039] The data acquisition module converts the electrical signals of the temperature sensor and the torque sensor into digital signals and transmits them to the data processing unit;

[0040] The data processing unit analyzes the temperature and torque data and generates real-time monitoring results;

[0041] The monitoring results are output through the display screen. If the temperature exceeds the threshold or the torque fluctuates abnormally, the operator adjusts the speed parameters or terminates the running-in process through the operation panel.

[0042] The present invention has the following beneficial effects:

[0043] 1. The present invention forms a vertical and horizontal bidirectional clamping structure by fixing the positioning base of the rapid positioning clamping device to the top of the frame, fixing the upper pressure assembly to the top of the positioning base via a mounting bracket, and fixing the side lift assembly to the side of the positioning base via a mounting base. This allows the gearbox specimen to be run-in to be pre-aligned through the positioning groove during clamping and to be fixed without gaps through the rapid advancement of the upper pressure and side lift assemblies, significantly improving the clamping efficiency and the stability of the specimen during the running-in process.

[0044] 2. This invention extends the inverter's control circuitry to the electrical control cabinet's operating panel and incorporates a speed parameter input interface on the panel. This allows for direct connection between the drive assembly's operating and control terminals. Operators can adjust the motor speed in real time through panel input without entering the control cabinet, simplifying the switching process between different operating conditions, such as low-speed running-in and high-speed testing, and improving the convenience of test operations.

[0045] 3. This invention electrically connects the temperature sensor and torque sensor to the data acquisition module and data processing unit in sequence, and connects the output of the data processing unit to the display screen on the front panel of the frame. This allows key parameters such as temperature and torque to be collected, processed, and visualized in real time during the running-in process. Operators can intuitively observe data changes and promptly detect abnormal conditions, effectively improving the reliability of monitoring the test results of internal components of the gearbox.

[0046] 4. The present invention realizes the integrated design of the clamping force adjustment function and the cylinder body by directly installing the air pressure regulating valve at the air source interface of the downward-pressing fixed cylinder and the cylinder propulsion device, and connecting it to the external air source through a pipeline. The operator can directly adjust the air pressure regulating valve to control the cylinder output pressure, flexibly adapting to the clamping requirements of gearboxes of different sizes or materials, avoiding the tedious steps of disassembly and adjustment of traditional mechanical clamps, and further improving the flexibility of the clamping process. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0048] Figure 2 This is a schematic structural diagram of the rapid positioning and clamping device of the present invention;

[0049] Figure 3 This is a structural diagram of the positioning base of the present invention;

[0050] Figure 4 For the present invention Figure 1 A magnified schematic diagram of part A in the middle;

[0051] Figure 5 It is a rear view of the present invention;

[0052] Figure 6 It is a left side view of the present invention;

[0053] Figure 7 Flow chart of the method of the present invention;

[0054] Figure 8 This is a flow chart of the gearbox clamping steps of the present invention;

[0055] Figure 9 This is a flow chart of the operation of the gearbox of the present invention after installation;

[0056] Figure 10 It is a parameter monitoring flow chart of the present invention.

[0057] Among them, 1-frame; 11-mounting bracket; 12-mounting base; 13-electrical control cabinet; 14-display screen; 2-quick positioning clamping device; 21-positioning base; 211-positioning slot; 22-clamping mechanism; 221-upper pressure assembly; 222-side top assembly; 2221-cylinder propulsion device; 2222-propulsion fixture; 3-drive assembly; 31-motor; 32-inverter; 4-control assembly; 41-temperature sensor; 42-torque sensor; 5-gearbox. DETAILED DESCRIPTION

[0058] The present invention will be further described in detail below with reference to the accompanying drawings and specific preferred embodiments.

[0059] In the description of the present invention, it should be understood that the terms "left side," "right side," "upper," "lower," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Terms such as "first" and "second" do not indicate the importance of components and therefore should not be construed as limitations on the present invention. The specific dimensions used in this embodiment are intended only to illustrate the technical solution and do not limit the scope of protection of the present invention.

[0060] Reference Figure 1 、 Figure 2 and Figure 3 It can be seen that the present invention is a gearbox running-in sample device with rapid positioning and clamping, with the frame 1 as the core bearing foundation, and the rapid positioning and clamping device 2, the drive component 3 and the control component 4 are all fixedly mounted on the frame 1. Among them, the positioning base 21 of the rapid positioning and clamping device 2 is fixedly mounted on the top of the frame 1, and the positioning groove 211 provided on its top surface is used to place the gearbox to be run-in; the upper pressure component 221 of the clamping mechanism 22 is fixed above the positioning base 21 through the mounting bracket 11, and the cylinder body of the downward pressure fixing cylinder is connected to the mounting bracket 11, and the piston rod extends vertically downward to above the positioning groove 211; the side top component 222 is fixed to the side of the positioning base 21 through the mounting seat 12, and the cylinder body of the cylinder propulsion device 2221 is connected to the mounting seat 12, and its piston rod is connected to the propulsion fixture 2222 and extends horizontally toward the positioning groove 211. The motor 31 of the drive assembly 3 is fixedly mounted on one side of the frame 1, its output shaft coaxially connected to the input shaft of the gearbox to be run-in via a coupling. The frequency converter 32 is fixedly mounted in the electrical control cabinet of the frame 1 and electrically connected to the motor 31 via wires. In the control assembly 4, the temperature sensor 41 and torque sensor 42 are fixed to the motor 31 via threaded connections or clamps. The data acquisition module is fixedly mounted on the frame 1, its signal input terminal electrically connected to the temperature sensor 41 and torque sensor 42 respectively via wires, and its signal output terminal is also connected to the data processing unit via wires. The data processing unit is fixedly mounted in the electrical control cabinet 13 of the frame 1, and its signal output terminal is electrically connected to the display screen 14 on the front panel of the frame 1. In addition, the air source interfaces of the downward-pressing fixed cylinder and the cylinder propulsion device 2221 are both equipped with air pressure regulating valves, which are connected to an external air source via pipelines. The control circuit of the frequency converter 32 extends to the operating panel of the electrical control cabinet, which has an input interface for speed parameters. The inner surface of the positioning groove 211 of the positioning base 21 is provided with anti-slip grooves, which contact and mate with the bottom surface of the gearbox to be run-in. These components are connected through the above mechanical fixation, electrical connection, and pneumatic pipelines to form an integrated rapid positioning specimen run-in device.

[0061] In one embodiment, referring to Figure 5 It can be seen that the gearbox to be run-in is first placed in the positioning groove 211 on the top surface of the positioning base 21. The positioning groove is adapted to the gearbox, and the anti-slip grooves on the inner surface increase the contact friction to prevent sliding. Subsequently, the downward pressure fixing cylinder of the upper pressure component 221 is activated, and the cylinder body is fixed to the frame 1 through the mounting bracket 11. The piston rod extends vertically downward to the top of the positioning groove 211 and presses the top of the gearbox. At the same time, the cylinder propulsion device 2221 of the side push component 222 is activated, and the cylinder body is fixed to the frame 1 through the mounting base 12. The piston rod pushes the tooling fixture 2222 to extend horizontally toward the positioning groove 211, pressing the gearbox from the side. Through the coordinated action of the upward pressure in the vertical direction and the side push in the horizontal direction, the gearbox is stably fixed in the positioning groove 211, completing the rapid positioning and clamping. The air pressure regulating valve is installed at the air source interface of the downward pressure fixing cylinder and the cylinder propulsion device 2221. By adjusting the air pressure input from the external air source, the propulsion force of the cylinder piston rod can be flexibly controlled to meet the clamping requirements of different gearboxes.

[0062] In one embodiment, the drive component 3 realizes power output control through the cooperation of the motor 31 and the frequency converter 32: the operator sets the target speed, such as the speed value of low-speed running-in or high-speed test, through the speed parameter input interface of the electrical control cabinet operation panel, and the frequency converter 32 adjusts the power supply parameters of the motor 31, such as frequency and voltage, after receiving the instruction; after the motor 31 is powered on, its output shaft is coaxially connected to the input shaft of the gearbox to be run-in through a coupling, converting electrical energy into mechanical energy to drive the internal components of the gearbox to operate, thereby completing the running-in test of the gearbox.

[0063] In one embodiment, the temperature sensor 41 and the torque sensor 42 are respectively fixed to the motor 31 by threaded connections or clamps, and collect the temperature data of the motor during operation and the torque data of the gearbox input shaft in real time; the data acquisition module is fixedly installed on the frame 1, receives the electrical signal of the sensor through the wire and converts it into a processable digital signal, and transmits it to the data processing unit; the data processing unit is fixed in the electrical control cabinet 13, analyzes the signal, such as whether the temperature is abnormal or whether the torque is stable, and the processed result is transmitted to the display screen 14 on the front panel of the frame 1 through the signal output end. The operator can observe the changes of key parameters in real time during the running-in process through the display screen.

[0064] The present invention further discloses a gearbox sample running-in method with rapid positioning and clamping, which uses a gearbox sample running-in device with rapid positioning and clamping to detect the internal structure of the gearbox, including the following steps:

[0065] S1. Sample positioning and clamping: The gearbox to be run-in is fixed in the positioning groove 211 of the quick positioning clamping device 2, and is clamped in coordination with the upper pressure assembly 221 and the side top assembly 222;

[0066] S2 drive running-in operation: drive assembly 3 to drive the gearbox to be run-in at a set speed to complete the running-in process;

[0067] S3. Real-time parameter monitoring and adjustment: The temperature and torque parameters during the running-in process are collected and analyzed by the control component 4, and the operating status is adjusted according to the monitoring results.

[0068] In step S1, the gearbox to be run-in is placed in the positioning groove 211 of the positioning base 21, so that the bottom surface of the gearbox contacts and fits with the anti-slip grooves on the inner surface of the positioning groove 211;

[0069] Start the downward pressing fixed cylinder of the upward pressing assembly 221, and the piston rod extends vertically downward to above the positioning groove 211 and presses the top of the gear box;

[0070] Synchronously start the cylinder propulsion device 2221 of the side push assembly 222, and the piston rod pushes the tooling fixture 2222 to extend horizontally toward the positioning groove 211 and press against the side of the gear box;

[0071] The air pressure regulating valve 223 is used to adjust the air pressure of the downward fixing cylinder and the cylinder propulsion device 2221 so that the clamping force meets the sample clamping requirements.

[0072] In step S2, the target speed is input through the speed parameter input interface of the control component 4;

[0073] The frequency converter 32 adjusts the power supply frequency and voltage parameters of the motor 31 after receiving the speed command;

[0074] The output shaft of the motor 31 is coaxially connected to the input shaft of the gearbox to be run-in through a coupling, driving the internal components of the gearbox to continuously operate at the set speed to complete the sample running-in process.

[0075] In step S3, the temperature sensor 41 collects the operating temperature data of the motor 31 in real time, and the torque sensor 42 collects the torque data of the input shaft of the gearbox to be run-in in real time;

[0076] The data acquisition module 43 converts the electrical signals of the temperature sensor 41 and the torque sensor 42 into digital signals and transmits them to the data processing unit 44;

[0077] The data processing unit 44 analyzes the temperature and torque data and generates real-time monitoring results;

[0078] The monitoring results are outputted via the display screen 14. If the temperature exceeds a threshold or the torque fluctuates abnormally, the operator adjusts the speed parameters or terminates the running-in process via the operation panel.

[0079] Temperature sensors and torque sensors 42 are installed at key locations of the gearbox, such as the transmission shaft and bearings. The temperature sensor 41 is used to monitor the temperature changes of the gearbox during the running-in process in real time, to prevent damage to parts due to overheating caused by improper operation during the assembly process, and to provide timely feedback; it also reflects the matching status and running stability of internal parts; the torque sensor 42 is used to measure the input and output torque of the gearbox 5 and evaluate the transmission efficiency of the gearbox 5.

[0080] The data acquisition module is connected to each sensor and is responsible for collecting the data collected by the sensor and transmitting it to the data processing unit.

[0081] The data processing unit analyzes the collected data and, using preset constant values ​​and models, determines the running-in condition of the gearbox's internal components, the fit between the drive shaft and bearings, and whether the machined dimensions of the components meet requirements. The analysis results are displayed in real time on the device's display and can be stored for subsequent query and analysis.

[0082] Three groups of gearboxes (A, B, and C) of the same model to be run-in were selected, and the run-in test was performed strictly according to steps S1 to S3. The total time taken from clamping to completion of the run-in and the repeatability of the test results were recorded for each group. The test results showed that the clamping time of the three groups of specimens was stable at 3-5 minutes, while traditional manual clamping required 10-15 minutes. The surface roughness (Ra value) of the gears after the three groups of specimens were 0.82μm, 0.85μm, and 0.83μm respectively after the run-in. This verified the efficiency of the standardized process and the repeatability of the results, and proved that the systematic step design effectively improved the test efficiency and reliability.

[0083] Two gearbox 5 samples made of different materials were selected and clamped on both sides of the frame 1 respectively. The gearbox 5 was tested at the same time. The output air pressure of the air pressure regulating valve 223 was set to 0.6 MPa. After clamping, the relative displacement of the sample and the positioning groove 211 was measured using a high-precision displacement sensor. The results showed that the maximum displacement in the horizontal or vertical direction did not exceed 0.05 mm. The air pressure was adjusted to 0.4 MPa (to avoid overpressure deformation). After clamping, the displacement also did not exceed 0.05 mm, and there was no indentation or damage on the surface of the sample. The design of the clamping structure 22 and the positioning base 21 significantly improved the clamping stability. The setting of the air pressure regulating valve 223 enables the device to flexibly adapt to samples of different materials, avoiding the risk of damage or displacement.

[0084] When testing the drive control accuracy:

[0085] Test 1: The target speed is set to 500 rpm through the speed parameter input interface. The inverter 32 adjusts the operation of the motor 31 and measures the actual speed fluctuation range of the internal parts of the gearbox 5.

[0086] Test 2: Set the target speed to 1500 rpm and repeat the above test.

[0087] When the same speed (e.g. 500 rpm) was tested five times in a row, the coaxiality error between the motor output shaft and the gearbox input shaft did not exceed 0.02 mm. The linkage design between the speed parameter input and the inverter 32 achieved precise drive control. The coaxial connection reduced power loss, ensuring the controllability of the running-in process and the scientific nature of the test data.

[0088] When monitoring and adjusting effectiveness testing:

[0089] Artificially increasing the motor load, such as gear jamming, caused the torque sensor 42's collected value to suddenly increase from the normal 12 N·m to 25 N·m. The threshold was set at 20 N·m. The monitoring system's response time from data collection to display screen alarm and triggering operator shutdown was 1.2 seconds. The motor was not damaged due to continuous overload.

[0090] The motor heat dissipation failure caused the temperature to rise from the normal 55°C to 85°C. The threshold was set at 70°C. After the system alarm, the operator reduced the speed within 3 seconds and the temperature dropped to 60°C within 5 seconds, avoiding the motor overheating and burning.

[0091] Dual parameter monitoring of temperature and torque and the real-time feedback mechanism can quickly identify anomalies and trigger intervention. The closed-loop control significantly improves the safety of the running-in process and avoids equipment damage and test failure.

[0092] Working principle: The gearbox to be run-in is first placed on the top of the frame 1. The inner positioning groove 211 of the positioning base 21 is adapted to the gearbox, and the anti-slip grooves on the inner surface increase the contact friction to prevent sliding. Then the downward pressure fixing cylinder of the upper pressure component 221 starts the cylinder body and is fixed to the frame through the mounting bracket 11. The piston rod presses the top of the gearbox vertically downward; at the same time, the cylinder propulsion device 2221 of the side top component 222 starts the cylinder body and is fixed to the frame through the mounting seat 12. The piston rod pushes the fixture 2222 to horizontally press the side of the gearbox, and a stable fixation is formed through vertical and horizontal two-way clamping. The air pressure regulating valve can adjust the cylinder air pressure and flexibly control the clamping force to adapt to different tests. Sample requirements; the operator sets the target speed through the speed parameter input interface of the electrical control cabinet operation panel, and the frequency converter 32 adjusts the power supply parameters of the motor 31 after receiving the command. The motor output shaft is coaxially connected to the gearbox input shaft through a coupling, driving the internal components of the gearbox to operate and realize running-in; during the running-in process, the temperature sensor 41 and the torque sensor 42 collect the motor temperature and gearbox input shaft torque data in real time, the data acquisition module converts the signal into a digital signal and transmits it to the data processing unit, and the processed result is presented in real time through the display screen 14. The operator can adjust or terminate the test in time by observing the parameter changes, and finally complete the efficient running-in test of the gearbox.

[0093] The preferred embodiments of the present invention are described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the technical concept of the present invention, various equivalent transformations can be made to the technical solutions of the present invention, and these equivalent transformations all fall within the scope of protection of the present invention.

Claims

1. A gearbox running-in sample device with rapid positioning and clamping, used for testing the internal parts of a gearbox (5), characterized in that: The quick positioning clamping device (2) is installed on the frame (1) and clamps the gear box (5) to be tested. The driving component (3) drives the internal components of the gear box (5) to operate. The operating parameters of the internal components of the gear box (5) are adjusted through the control component (4) and the operating parameters are displayed on the display screen (14).

2. The gearbox running-in sample device with rapid positioning and clamping according to claim 1, characterized in that: It comprises a frame (1), a quick positioning clamping device (2), a driving component (3) and a control component (4); The quick positioning clamping device (2), the driving component (3) and the control component (4) are all fixedly mounted on the frame (1); The rapid positioning and clamping device (2) comprises a positioning base (21) and a clamping mechanism (22); the positioning base (21) is fixedly mounted on the top of the frame (1); a positioning groove (211) is provided on the top surface of the positioning base (21); the clamping mechanism (22) comprises an upper pressing component (221) and a side top component (222); the upper pressing component (221) is fixedly mounted above the positioning base (21) via a mounting bracket (11); and the side top component (222) is fixedly mounted on the side of the positioning base (21) via a mounting seat (12); The drive assembly (3) includes a motor (31) and a frequency converter (32), wherein the motor (31) is fixedly mounted on one side of the frame (1), and its output shaft is coaxially connected to the input shaft of the gearbox to be run-in via a coupling; the frequency converter (32) is fixedly mounted in an electrical control cabinet of the frame (1) and is electrically connected to the motor (31) via a wire; The control assembly (4) comprises a temperature sensor (41), a torque sensor (42), a data acquisition module and a data processing unit; the temperature sensor (41) and the torque sensor (42) are respectively fixed to the motor (31) by threaded connection or clamp; the data acquisition module is fixedly mounted on the frame (1); the signal input end of the data acquisition module is electrically connected to the temperature sensor (41) and the torque sensor (42) by wires, and the signal output end of the data acquisition module is electrically connected to the data processing unit by wires; the data processing unit is fixedly mounted in an electrical control cabinet (13) of the frame (1).

3. The gearbox running-in sample device with rapid positioning and clamping according to claim 2, characterized in that: The upper pressure assembly (221) includes a downward pressure fixed cylinder, the cylinder body of the downward pressure fixed cylinder is fixedly connected to the frame (1) through the mounting bracket (11), and the piston rod of the downward pressure fixed cylinder extends vertically downward to above the positioning groove (211); The side top assembly (222) comprises a cylinder propulsion device (2221) and a propulsion fixture (2222); the cylinder body of the cylinder propulsion device (2221) is fixedly connected to the frame (1) via a mounting seat (12); the propulsion fixture (2222) is fixedly connected to the piston rod of the cylinder propulsion device (2221) and extends horizontally toward the positioning groove (211).

4. The gearbox running-in sample device for rapid positioning and clamping according to claim 3 is characterized in that: Air pressure regulating valves are installed at the air source interfaces of the downward-pressing fixed cylinder and the cylinder propulsion device (2221), and the air pressure regulating valves are connected to the external air source through pipelines.

5. The gearbox running-in sample device with rapid positioning and clamping according to claim 5 is characterized in that: The control circuit of the frequency converter (32) extends to the operation panel of the electrical control cabinet, and the operation panel is provided with a speed parameter input interface.

6. The gearbox running-in sample device with rapid positioning and clamping according to claim 2, characterized in that: The signal output end of the data processing unit is electrically connected to the display screen (14) of the rack (1), and the display screen (14) is fixedly mounted on the front panel of the rack (1).

7. The gearbox running-in sample device with rapid positioning and clamping according to claim 2, characterized in that: The positioning groove (211) is adapted to the gearbox to be run-in, and the inner surface of the positioning groove (211) of the positioning base (21) is provided with anti-skid grooves, and the anti-skid grooves are in contact with the bottom surface of the gearbox to be run-in.

8. A method for running-in a gearbox specimen with rapid positioning and clamping, characterized in that: The gearbox running-in sample device with rapid positioning and clamping as described in claims 1 to 7 is used to detect the internal structure of the gearbox, including the following steps: S1. Sample positioning and clamping: The gearbox to be run-in is fixed in the positioning groove (211) of the quick positioning clamping device (2), and is clamped collaboratively by the upper pressure assembly (221) and the side top assembly (222); S2 drive running-in operation: through the drive assembly (3) drives the gearbox to be run-in at a set speed to complete the running-in process; S3. Real-time parameter monitoring and adjustment: The temperature and torque parameters during the running-in process are collected and analyzed through the control component (4), and the operating status is adjusted according to the monitoring results.

9. The gearbox specimen running-in method with rapid positioning and clamping according to claim 8, characterized in that: The step S1 specifically includes: The gearbox to be run-in is placed in the positioning groove (211) of the positioning base (21), so that the bottom surface of the gearbox contacts and fits with the anti-slip grooves on the inner surface of the positioning groove (211); The downward pressing fixed cylinder of the upward pressing assembly (221) is activated, and the piston rod extends vertically downward to above the positioning groove (211) and presses the top of the gear box; Synchronously start the cylinder propulsion device (2221) of the side push assembly (222), and the piston rod pushes the propelling fixture (2222) to extend horizontally toward the positioning groove (211) and press against the side of the gear box; The air pressure of the air source of the downward-pressing fixed air cylinder and the air cylinder propulsion device (2221) is adjusted by the air pressure regulating valve (223) so that the clamping force meets the sample clamping requirements.

10. The gearbox specimen running-in method with rapid positioning and clamping according to claim 8, characterized in that: The step S2 specifically includes: Inputting a target speed through a speed parameter input interface of a control component (4); The frequency converter (32) adjusts the power supply frequency and voltage parameters of the motor (31) after receiving the speed command; The output shaft of the motor (31) is coaxially connected to the input shaft of the gearbox to be run-in through a coupling, driving the internal components of the gearbox to continuously operate at a set speed to complete the sample running-in process.

11. The gearbox specimen running-in method with rapid positioning and clamping according to claim 8, characterized in that: The step S3 specifically includes: The temperature sensor (41) collects the operating temperature data of the motor (31) in real time, and the torque sensor (42) collects the torque data of the input shaft of the gearbox to be run-in in real time; The data acquisition module (43) converts the electrical signals of the temperature sensor (41) and the torque sensor (42) into digital signals and transmits them to the data processing unit (44); The data processing unit (44) analyzes the temperature and torque data to generate real-time monitoring results; The monitoring result is outputted via a display screen (14). If the temperature exceeds a threshold or the torque fluctuates abnormally, the operator adjusts the speed parameter or terminates the running-in process via the operation panel.

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