Testing device and method for touring car jacking mechanism

Abstract

The invention relates to the technical field of vehicle equipment testing, discloses a testing device and method for a motor home jacking mechanism, and solves the problems of low testing efficiency and insufficient precision caused by the fact that traditional jacking mechanism testing is mostly carried out through manual load adjustment and data recording. The testing device comprises a frame, and a jacking mechanism to be tested is fixed in the frame; the simulation load mechanism is respectively connected with the frame and the jacking mechanism; the force sensor is used for measuring the load force transmitted to the jacking mechanism by the simulation load mechanism; and the controller is used for controlling the simulation load mechanism to apply a constant test load to the jacking mechanism along a preset direction according to a preset load parameter and a load force numerical value measured by the force sensor, and controlling the jacking mechanism to perform jacking along a direction opposite to the preset direction so as to confirm whether the jacking mechanism meets a preset jacking requirement or not.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of vehicle equipment testing, in particular to a test device and method for a motor home roof lifting mechanism. BACKGROUND

[0002] The motor home roof lifting mechanism is a core component for realizing the lifting function of the roof of a motor home, and its reliability directly affects the safety and comfort of the motor home. In the research and development and production process, the load bearing capacity, lifting height, speed and other performance parameters of the roof lifting mechanism need to be tested. The traditional roof lifting mechanism test is mostly carried out by manually adjusting the load and recording data, which leads to low test efficiency and insufficient precision. SUMMARY

[0003] The present application provides a test device and method for a motor home roof lifting mechanism, aiming to solve the problem that the traditional roof lifting mechanism test is mostly carried out by manually adjusting the load and recording data, which leads to low test efficiency and insufficient precision.

[0004] In a first aspect, the present application provides a test device for a motor home roof lifting mechanism, comprising: a frame, the roof lifting mechanism to be tested is fixed inside the frame; a simulated load mechanism, the simulated load mechanism is connected with the frame and the roof lifting mechanism respectively; a force sensor, the force sensor is used to measure the load force transmitted by the simulated load mechanism to the roof lifting mechanism; a controller, the controller is used to control the simulated load mechanism to apply a constant test load to the roof lifting mechanism along a preset direction according to a preset load parameter and the load force value measured by the force sensor, and control the roof lifting mechanism to lift in the opposite direction of the preset direction, so as to confirm whether the roof lifting mechanism meets the preset lifting requirement and complete the test of the roof lifting mechanism.

[0005] In some embodiments, one end of the roof lifting mechanism is fixedly connected with the bottom plate of the frame; the test device further comprises a connecting plate, the other end of the roof lifting mechanism is fixedly connected with the connecting plate, and the simulated load mechanism is arranged above the connecting plate, so that the simulated load mechanism applies the test load to the roof lifting mechanism through the connecting plate.

[0006] In some embodiments, the test device further comprises a guide rail, the guide rail is fixed inside the frame, and the connecting plate is movably connected with the guide rail, so as to control the roof lifting mechanism to move along the preset direction or the opposite direction of the preset direction.

[0007] In some embodiments, the top plate of the frame is provided with a through hole; the simulated load mechanism comprises a fixed part fixed to the top plate through the through hole, and a telescopic part having one end movably connected to the fixed part and the other end connected to the connecting plate through the force sensor.

[0008] In some embodiments, the testing device further comprises a displacement sensor for measuring the displacement of the lifting mechanism.

[0009] In some embodiments, the preset lifting requirement at least comprises a preset lifting height requirement; the controller obtains the maximum lifting height of the lifting mechanism corresponding to the testing load according to the displacement information measured by the displacement sensor, to determine whether the preset lifting height requirement is met.

[0010] In some embodiments, the preset lifting requirement at least further comprises a preset lifting speed requirement; the controller obtains the real-time lifting speed of the lifting mechanism corresponding to the testing load according to the displacement information measured by the displacement sensor, to determine whether the preset lifting speed requirement is met.

[0011] In a second aspect, the application provides a testing method of a motor home lifting mechanism, which is applied to the controller of any one of the motor home lifting mechanisms provided by the application, and the method comprises the following steps: obtaining preset load parameters corresponding to the lifting mechanism; controlling the simulated load mechanism to apply a constant testing load to the lifting mechanism along a preset direction according to the preset load parameters and the load force value; controlling the lifting mechanism to lift in the opposite direction of the preset direction to determine whether the lifting mechanism meets preset lifting requirements, thereby completing the testing of the lifting mechanism.

[0012] In some embodiments, if the lifting mechanism meets the preset lifting requirements under the testing load, the method further comprises the following steps: sequentially controlling the value of the testing load to increase according to a preset adjustment rule; after each time the testing load is increased, sequentially controlling the lifting mechanism to lift in the opposite direction of the preset direction until the lifting mechanism does not meet the preset lifting requirements, obtaining the value of the corresponding testing load and determining the value as the limit load of the lifting mechanism.

[0013] In some embodiments, the preset lifting requirement comprises at least a preset lifting speed and a preset lifting height; and the determining whether the lifting mechanism meets the preset lifting requirement comprises: determining whether the preset lifting speed is met according to a real-time lifting speed of the lifting mechanism corresponding to the lifting process; and determining whether the preset lifting height is met according to a maximum lifting height of the lifting mechanism corresponding to the lifting process.

[0014] The application can simulate the actual working conditions that may be faced in the lifting process of the motor home by making the load application direction of the simulation load mechanism and the lifting direction of the lifting mechanism collinear, thereby improving the reliability of the test results. The load force value is measured in real time by the force sensor, the controller dynamically adjusts the simulation load in combination with the preset load parameters, and simultaneously controls the movement of the lifting mechanism, thereby realizing the synchronous monitoring and evaluation of the lifting height, speed and other parameters, and ensuring that the test covers multi-dimensional performance indicators. The controller can adjust the lifting control signal in real time according to the displacement information of the distance sensor, forming a closed-loop control, which not only improves the test efficiency, but also provides data support for the optimization design of the lifting mechanism.

[0015] It should be understood that the foregoing general description and the following detailed description are only exemplary and explanatory, and cannot limit the application. BRIEF DESCRIPTION OF DRAWINGS

[0016] In order to more clearly illustrate the technical solutions of the embodiments of the application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.

[0017] Figure 1 is a front view of a test device for a motor home lifting mechanism in a compressed state according to an embodiment of the application; Figure 2 is a perspective view of a test device for a motor home lifting mechanism in a compressed state according to an embodiment of the application; Figure 3 is a front view of a test device for a motor home lifting mechanism in an extended state according to an embodiment of the application; Figure 4 is a perspective view of a test device for a motor home lifting mechanism in an extended state according to an embodiment of the application; Figure 5 is a step schematic flow chart of a test method for a motor home lifting mechanism according to an embodiment of the application; Figure 6 is a structural schematic block diagram of a controller according to an embodiment of the application.

[0018] It is to be understood that the foregoing general description and the following detailed description are only exemplary and explanatory and are not restrictive of the application. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present application.

[0020] The flowcharts shown in the drawings are only exemplary and are not necessarily required to include all the contents and operations / steps, and are not necessarily required to be executed in the described order. For example, some operations / steps can be further decomposed, combined or partially merged, and thus the actual execution order can be changed according to the actual situation.

[0021] It should be understood that, in order to clearly describe the technical solutions of the embodiments of the present application, in the embodiments of the present application, the terms "first", "second", etc. are used to distinguish the same items or similar items with basically the same functions and effects. Those skilled in the art can understand that the terms "first", "second", etc. do not limit the quantity and execution order, and the terms "first", "second", etc. also do not necessarily mean that they are different.

[0022] It should be understood that the terms used in the present application specification are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the present application specification and the appended claims, unless otherwise clearly indicated by the context, the singular forms "a", "an" and "the" are intended to include the plural forms.

[0023] It should also be understood that the term "and / or" used in the present application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes these combinations.

[0024] Some embodiments of the present application will be described in detail below with reference to the accompanying drawings. The following embodiments and features in the embodiments can be combined with each other without conflict.

[0025] The RV roof lifting mechanism is the core component for realizing the RV roof lifting function, and its reliability directly affects the safety and comfort of the RV. In the research and production process, the load bearing capacity, lifting height, speed and other performance parameters of the roof lifting mechanism need to be tested. The traditional roof lifting mechanism test is mostly performed by manually adjusting the load and recording data, which leads to low test efficiency and insufficient accuracy.

[0026] To solve the above problems, please refer to Figures 1-4 The application provides a test device for a motor home roof lifting mechanism, comprising: a frame 10, the roof lifting mechanism 200 to be tested is fixed inside the frame 10; a simulated load mechanism 20, the simulated load mechanism 20 is connected with the frame 10 and the roof lifting mechanism 200 respectively; a force sensor 40, the force sensor 40 is used to measure the load force transmitted by the simulated load mechanism 20 to the roof lifting mechanism 200; a controller, the controller is used to control the simulated load mechanism 20 to apply a constant test load to the roof lifting mechanism 200 along a preset direction according to a preset load parameter and the load force value measured by the force sensor 40, and control the roof lifting mechanism 200 to lift in the opposite direction of the preset direction to confirm whether the roof lifting mechanism 200 meets the preset lifting requirement, and complete the test of the roof lifting mechanism 200.

[0027] Specifically, the test device aims to solve the problems of low efficiency and insufficient precision in traditional manual testing of the motor home roof lifting mechanism 200, and realizes precise testing of core performance parameters such as load bearing capacity, lifting height and speed of the roof lifting mechanism 200 through automatic control. The device mainly consists of four core parts: frame 10, simulated load mechanism 20, force sensor 40 and controller. Through closed-loop control logic, dynamic adjustment of simulated load and automatic testing of lifting process are realized to ensure the reliability and efficiency of test results.

[0028] The frame 10 serves as a basic support structure, providing a fixed installation space for the roof lifting mechanism 200 and providing a counterforce support point for the simulated load mechanism 20. It is made of high-strength metal materials such as aluminum alloy or steel, and has standardized installation interfaces inside, which can adapt to different models of roof lifting mechanisms 200. The frame 10 has connection nodes for the simulated load mechanism 20 reserved at the top or side, ensuring that the load application direction and the lifting motion direction are coaxial.

[0029] The simulated load mechanism 20 is used to apply a constant or dynamic load in a preset direction (such as vertically downward) to the roof lifting mechanism 200 according to the controller instructions, simulating the actual load (such as the weight of the roof, wind resistance load, etc.) during the lifting of the motor home. It can be connected to the force receiving end (such as the upper base) of the roof lifting mechanism 200 through mechanical connection (such as threaded connection, pin connection, etc.) in the form of electric push rod, hydraulic cylinder or air cylinder, etc., ensuring that the load direction and the lifting motion direction are reverse and collinear.

[0030] The force sensor 40 is used to measure the load force (i.e. load force) transmitted by the simulated load mechanism 20 to the roof lifting mechanism 200 in real time, providing feedback signals for the controller. It can be set in the connection path between the simulated load mechanism 20 and the roof lifting mechanism 200 (such as integrating a strain type force sensor 40 on the connecting rod or connecting piece), facilitating direct collection of force signals.

[0031] The controller employs a PLC (Programmable Logic Controller), industrial computer or embedded control system, integrating data acquisition module, drive module and human-machine interface (HMI). Through the built-in control algorithm, it supports the input of preset load parameters (such as target load force, lifting speed threshold, height threshold), and realizes closed-loop control (such as PID regulation) according to the feedback of force sensor 40.

[0032] The test process and control logic corresponding to the exemplary test device include: 1. Initial installation and parameter setting: Fix the lifting mechanism 200 to be tested inside the frame 10, ensure that its movement direction (such as vertical direction) is strictly coaxial and opposite to the load application direction of the simulated load mechanism 20. Through the controller's human-machine interface, input the preset load parameters (such as rated load force 1000N, target lifting height 800mm, speed upper limit 50mm / s), and set the test mode (such as static load test, dynamic lifting test).

[0033] 2. Simulated load application and closed-loop control: The controller drives the simulated load mechanism 20 to apply load in the preset direction (such as downward), while collecting force sensor 40 data in real time, adjusting the load mechanism output through closed-loop algorithm until the load force stabilizes at the preset load value (such as 1000N±1%), realizing precise control of constant load. If the force sensor 40 feedback value deviates from the preset value, the controller automatically adjusts the output of the simulated load mechanism 20 (such as increasing the electric push rod thrust or hydraulic pressure), ensuring that the load remains constant during the test process, avoiding manual intervention errors.

[0034] 3. Lifting mechanism 200 drive and performance monitoring: When the simulated load is stable, the controller sends a lifting command to the lifting mechanism 200 to drive it to move in the opposite direction (such as upward), while starting the following monitoring: Load bearing capacity: Monitor the load force fluctuation during lifting through the force sensor 40 in real time, judge whether the lifting mechanism 200 can run stably under constant load, and whether there is overload or load mutation anomaly. Lifting height: Measure the actual lifting height with displacement sensor (optional or through frame 10 ruler assistance), compare with the preset height threshold, verify whether it meets the standard. Lifting speed: Calculate the average speed through displacement sensor data and time difference, or preset speed sensor interface in the controller, ensure that the running speed is within the safe range.

[0035] 4. Data recording and result determination: The controller records parameters such as force, displacement, time in real time, generates test curves (such as load-displacement curve, speed-time curve), and automatically stops the test when the top is raised to the position or abnormally stopped. The system automatically determines according to the preset standard: if the load fluctuation is within ±5% during the top raising process, the actual height is greater than or equal to the target height, the speed is less than or equal to the upper limit value, and there is no abnormality such as jamming and abnormal sound, it is determined that "it meets the preset top raising requirement"; otherwise, mark the fault point (such as insufficient load, speed over limit), and prompt manual review.

[0036] 5. Test mode expansion: no-load test: simulate the zero load applied by the load applying mechanism 20 to test the smoothness of the no-load operation of the top raising mechanism 200. Overload test: gradually increase the load to 1.5 times the rated value to verify the safety redundancy of the mechanism. Cycle life test: set multiple top raising-top lowering cycles to monitor the reliability of long-term operation (need to cooperate with life counter).

[0037] The dynamic calibration of the load is realized through the feedback of the force sensor 40, avoiding the hysteresis of traditional manual adjustment, and the precision is improved. Through one test, the core indicators such as load, height and speed can be covered, and the efficiency is improved compared with manual test. The frame 10 and the simulation load mechanism 20 support modular adjustment, which is suitable for different specifications of the top raising mechanism 200 (such as manual, electric and hydraulic).

[0038] The present application is suitable for the research and development test and factory inspection of the top raising mechanism 200 of the motor home manufacturer and the parts supplier, which can simulate the real working condition (such as different load and lifting frequency) in the laboratory environment to ensure the safety and comfort of the product in complex scenes. Through the standardized test process, data support is provided for the optimization design and reliability certification of the top raising mechanism 200.

[0039] In some embodiments, one end of the top raising mechanism 200 is fixedly connected with the bottom plate 12 of the frame 10; the test device further comprises a connecting plate 30, the other end of the top raising mechanism 200 is fixedly connected with the connecting plate 30, and the simulation load mechanism 20 is arranged above the connecting plate 30, so that the simulation load mechanism 20 applies the test load to the top raising mechanism 200 through the connecting plate 30.

[0040] Through the connecting plate 30 as the intermediate connecting piece of the top raising mechanism 200 and the simulation load mechanism 20, the load applying path is clear: one end of the top raising mechanism 200 is fixed to the bottom plate 12 of the frame 10, and the other end receives the test load of the simulation load mechanism 20 through the connecting plate 30, ensuring that the load is uniformly and vertically transmitted to the force receiving end of the top raising mechanism 200.

[0041] The bottom of the lifting mechanism 200 (such as the lower base) is fixed on the bottom plate 12 of the frame 10 by bolts or buckles, ensuring that the fixed end has no displacement. The top output end (such as the upper base) of the lifting mechanism 200 is fixedly connected (such as welded or bolted) to the center of the connecting plate 30, and the connecting plate 30 serves as a force-bearing intermediate body. The simulation load mechanism 20 (such as an electric push rod or a hydraulic cylinder) is arranged above the connecting plate 30, and the output end (such as the head of the push rod) thereof is in contact with or connected to the upper surface of the connecting plate 30, and the load direction is vertically downward (the preset direction). The load force is transmitted to the top of the lifting mechanism 200 through the connecting plate 30, forming a force transmission path of “frame 10 bottom plate 12→lifting mechanism 200→connecting plate 30→simulation load mechanism 20”, and ensuring that the load is applied along the axis direction of the lifting mechanism 200.

[0042] In some embodiments, the test device further comprises a guide rail 13 fixed inside the frame 10, and the connecting plate 30 is movably connected to the guide rail 13 to control the movement of the lifting mechanism 200 along the preset direction or the opposite direction of the preset direction.

[0043] By adding the guide rail 13 inside the frame 10 and movably connecting the connecting plate 30 to the guide rail 13, the movement direction of the lifting mechanism 200 is restricted, ensuring smooth movement in the preset direction (such as the vertical direction) or the opposite direction, avoiding test errors caused by lateral deviation, and improving movement accuracy and stability.

[0044] The guide rail 13 is installed by vertically fixing linear guide rails 13 (such as H-shaped or U-shaped guide rails 13) on both sides or around the frame 10. The direction of the guide rail 13 is strictly parallel to the movement direction (the opposite direction of the preset direction, such as vertically upward) of the lifting mechanism 200, and the length of the guide rail 13 covers the maximum stroke of the lifting mechanism 200. Sliders (such as ball sliders or linear bearings) matching the guide rail 13 can be arranged on both sides of the connecting plate 30, and the sliders are embedded in the sliding grooves of the guide rail 13, so that the connecting plate 30 can only slide along the direction of the guide rail 13, limiting the transverse degree of freedom.

[0045] The output end (such as the upper base) of the lifting mechanism 200 is fixedly connected to the connecting plate 30, and the movement thereof is restricted by the guide rail 13 through the connecting plate 30, ensuring that only linear movement in the preset direction (the opposite direction) is performed during the lifting process, and eliminating the interference of lateral force on the test load (for example, avoiding eccentricity of the load force caused by inclination).

[0046] In some embodiments, the top plate 11 of the frame 10 is provided with a through hole; the simulation load mechanism 20 comprises a fixed part 21 fixed to the through hole; and a telescopic part 22 movably connected to one end of the fixed part 21 and connected to the connecting plate 30 through the force sensor 40 at the other end.

[0047] By setting a through hole on the top plate 11 of the frame 10, the load simulation mechanism 20 is connected to the through hole through the fixing part 21, and the telescopic part 22 is connected to the connecting plate 30 through the force sensor 40, forming a load application channel through the frame 10, ensuring that the load direction is consistent with the lifting motion direction, and facilitating the integrated installation of the force sensor 40.

[0048] By setting a circular or square through hole in the center of the top plate 11 of the frame 10, the diameter or side length is slightly larger than the outer diameter of the telescopic part 22 of the load simulation mechanism 20, ensuring that the telescopic part 22 can freely reciprocate.

[0049] The load simulation mechanism 20 is composed of: the fixing part 21 is fixed on the top plate 11 of the frame 10 through the through hole, serving as the mounting base of the telescopic part 22 (such as an electric push rod or a gas cylinder), ensuring that the axial direction of the load simulation mechanism is consistent with the axial direction of the through hole. One end of the telescopic part 22 is movably connected to the fixing part 21, and the other end is connected to the upper surface (such as the center) of the connecting plate 30 through the force sensor 40 (such as the force sensor 40 having threads at both ends, one end screwed into the end of the telescopic part 22, and the other end screwed into the connecting hole of the connecting plate 30). When the telescopic part 22 extends downward, the load force is transmitted to the connecting plate 30 through the force sensor 40, and the force sensor 40 directly measures the load force. At the same time, the top plate 11 of the frame 10 provides counterforce support for the fixing part 21, forming an axial load transmission of “telescopic part 22 → force sensor 40 → connecting plate 30 → lifting mechanism 200”, avoiding partial load.

[0050] In some embodiments, the test device further comprises a displacement sensor for measuring the displacement of the lifting mechanism 200.

[0051] By adding a displacement sensor to measure the displacement (i.e. lifting height) of the lifting mechanism 200 in real time, accurate position feedback is provided to the controller, enabling quantitative testing of lifting height, speed and other parameters, and making up for the deficiency of the force sensor 40 alone in monitoring displacement.

[0052] The sensor type is selected as a linear displacement sensor (such as an infrared distance sensor or an ultrasonic distance sensor), and the installation method is selected according to actual needs, such as installing the transmitting end on the lower part of the connecting plate and the receiving end on the bottom plate 12 of the frame 10. The signal output end of the displacement sensor (such as 4-20mA or RS485) is connected to the data acquisition module of the controller, and the signals are collected synchronously with the force sensor 40, ensuring consistent timestamps.

[0053] In some embodiments, the preset lifting requirement at least includes a preset lifting height requirement; the controller acquires the maximum lifting height of the lifting mechanism 200 under the test load according to the displacement information measured by the displacement sensor, to determine whether it meets the preset lifting height requirement.

[0054] The controller uses displacement data from displacement sensors to calculate the maximum lifting height of the lifting mechanism 200 under test load, compares it with a preset height threshold, and determines whether the lifting height requirement is met, thus solving the problem of inconvenience in traditional manual height measurement.

[0055] The preset lifting height (e.g., 800mm) is input through the controller's human-machine interface, with a default allowable error range (e.g., ±2mm). The controller reads the displacement value from the displacement sensor in real time. When the lifting mechanism 200 stops moving (reaches its limit position or receives a stop command), the current maximum displacement value is recorded as the actual lifting height. If the actual height is greater than or equal to the preset height minus the allowable error, it is determined to "meet the height requirement"; otherwise, it is marked as "insufficient height," and the actual height and the difference are recorded in the test report, indicating that the mechanism may have insufficient load-bearing capacity or mechanical jamming.

[0056] In some embodiments, the preset lifting requirement includes at least a preset lifting speed requirement; the controller obtains the real-time lifting speed of the lifting mechanism 200 under the test load based on the displacement information measured by the displacement sensor, in order to confirm whether it meets the preset lifting speed requirement.

[0057] The controller calculates the real-time speed (average speed or instantaneous speed) during the lifting process based on the displacement-time data from the displacement sensor. It compares the speed with the preset speed threshold to verify whether the operating speed of the lifting mechanism 200 under load meets safety or design requirements, thus avoiding excessive speed causing impact or excessively slow speed affecting the user experience.

[0058] Speed ​​calculation includes: Average speed is calculated by selecting the displacement change (e.g., from 50mm to 250mm) during the stable movement phase of the lifting process and the corresponding time difference, resulting in the average speed (v=Δs / Δt). Instantaneous speed is calculated by using high-frequency sampling (e.g., 100Hz) from displacement sensors and calculating the ratio of the displacement difference between two adjacent sampling points to the time interval, thus monitoring instantaneous speed fluctuations in real time. Preset parameters are set in the controller with an upper speed limit (e.g., 10mm / s) and a lower speed limit (e.g., 5mm / s), and the threshold is adjusted according to the type of lifting mechanism (electric / hydraulic). If all real-time speeds during the entire lifting process are within the preset range and the average speed meets the design value, it is determined that the "speed meets the standard." If the instantaneous speed exceeds the upper limit (which may cause impact) or falls below the lower limit (which may indicate jamming), an alarm is triggered and the abnormal point is recorded, indicating excessive mechanical resistance or insufficient power of the power system.

[0059] This application simulates the actual working conditions that a motorhome might face during the roof-raising process by aligning the load application direction of the simulated load mechanism 20 with the lifting direction of the roof-raising mechanism 200, thereby improving the reliability of the test results. The load force is measured in real time by the force sensor 40, and the controller dynamically adjusts the simulated load based on preset load parameters, while simultaneously controlling the movement of the roof-raising mechanism 200. This enables synchronous monitoring and evaluation of parameters such as lifting height and speed, ensuring that the test covers multiple performance indicators. The controller can adjust the roof-raising control signal in real time based on the displacement information from the distance sensor, forming a closed-loop control, which not only improves testing efficiency but also provides data support for the optimized design of the roof-raising mechanism 200.

[0060] Please see Figure 5 , Figure 5 This is a schematic flowchart illustrating a testing method for a RV pop-up roof mechanism according to an embodiment of this application. The device executing the method is a controller deployed in the testing apparatus for the RV pop-up roof mechanism provided in any embodiment of this application.

[0061] like Figure 5 As shown, the provided method includes steps S101 to S103. The controller can be a handheld terminal, a laptop computer, a wearable device, or a robot, etc. This is used to implement steps S101 to S103 and their corresponding embodiments.

[0062] Step S101. Obtain the preset load parameters corresponding to the lifting mechanism.

[0063] Specifically, the controller obtains the preset load parameters required for testing through human-machine interaction or data interface, including target load force, lifting height threshold, speed threshold, number of test cycles, etc., to provide benchmark data for subsequent load application and performance judgment.

[0064] For example, parameter input methods include: Human-Machine Interface (HMI) input: The controller is equipped with a touch screen or button panel, allowing testers to manually input parameters through the interface (e.g., inputting a target load force of 1500N, a target lifting height of 280mm, and a speed limit of 8mm / s in the "Load Settings" interface). Parameters support unit conversion (N / kgf) and precision settings (retaining one decimal place). File / Database Import: Supports loading preset parameter templates (e.g., standard test parameters for a specific lifting mechanism model) from local files (e.g., Excel, JSON) or cloud databases, enabling rapid configuration for batch testing. Automatic Identification and Adaptation: The controller automatically matches the corresponding test standards in the preset parameter library (e.g., the rated load differences between different specifications of lifting mechanisms) by reading the lifting mechanism's model code (e.g., RFID tag, QR code), avoiding human input errors.

[0065] The controller performs logical verification on input parameters, such as ensuring the target load force is greater than 0, the lifting height threshold does not exceed the frame guide rail travel (automatically calibrated via the maximum range of the displacement sensor), and the speed threshold complies with the safety range of the power system (e.g., the upper limit of the electric push rod speed ≤ 15mm / s). Abnormal parameters trigger an input error message. Valid parameters are stored in the controller's memory or an external storage device, supporting the query and retrieval of historical test parameters, facilitating the standardization of the testing process.

[0066] Step S102. Control the simulated load mechanism to apply a constant test load to the lifting mechanism along a preset direction according to the preset load parameters and the load force value.

[0067] Specifically, the controller adjusts the output of the simulated load mechanism based on real-time feedback from the force sensor through a closed-loop control algorithm, so that the load force applied to the lifting mechanism is stabilized at a preset value, ensuring the high accuracy and constancy of the test load and eliminating the lag and deviation of manual adjustment.

[0068] The controller sends initialization commands to the simulated load mechanism (such as resetting the electric push rod to its initial position and depressurizing the hydraulic system) to ensure that the load mechanism is in a zero-load state and the connecting plate is in the initial position of the frame base plate (displacement sensor is zeroed). A force sensor signal acquisition channel is established, and the sampling frequency is set (such as 100Hz) to ensure real-time capture of load force fluctuations.

[0069] The target value setting uses the target load force in the preset load parameters (such as F_set=1200N) as the control target, and outputs the initial control signal (such as the voltage / current value of the electric actuator and the opening degree of the hydraulic valve) through the drive module.

[0070] Feedback adjustment uses a force sensor to collect the current load force F_real in real time. The controller calculates the deviation ΔF = F_set - F_real and uses a PID control algorithm (proportional-integral-derivative control) to dynamically adjust the output of the simulated load mechanism: if F_real < F_set (insufficient load), the electric actuator thrust or hydraulic pressure is increased until F_real approaches F_set; if F_real > F_set (overload), the output force is reduced and an alarm is triggered to prevent damage to the lifting mechanism. When F_real remains stable within a preset error range (e.g., ±1%F_set) for more than 5 seconds, the controller determines that the load application is complete and enters the lifting preparation state.

[0071] Multi-load modes support include: Static constant load: used for routine performance testing, the load force remains constant at F_set throughout the process; Gradient load: supports segmented loading (e.g., gradually increasing from 500N to the rated load of 1500N) to test the load adaptability of the lifting mechanism, and lifting is carried out only after the load of each stage has stabilized.

[0072] Step S103. Control the roof-lifting mechanism to lift the roof in the opposite direction of the preset direction to confirm whether the roof-lifting mechanism meets the preset roof-lifting requirements, and complete the test of the roof-lifting mechanism.

[0073] Specifically, the controller drives the roof-lifting mechanism to move upward (the preset opposite direction), synchronously collects displacement, force, and time data, determines whether the roof-lifting height, speed, and load stability meet the standards through preset rules, outputs the test results, and records the abnormalities to achieve automatic performance evaluation.

[0074] The controller sends a roof-lifting instruction (such as a PWM signal, a relay switch signal) to the power unit of the roof-lifting mechanism (such as a motor driver, a hydraulic pump controller), drives the mechanism to move upward along the guide rail (the preset opposite direction, vertically upward), and the connecting plate moves synchronously with the roof-lifting mechanism.

[0075] The displacement sensor outputs the position data S(t) of the connecting plate in real time, with an accuracy of 0.1 mm; the force sensor continuously monitors the load force F(t) to identify whether there is a load mutation (such as ΔF > 10%F_set, which may be caused by jamming); the built-in timer of the controller records the start time t_start and the end time t_end of the roof-lifting, with a resolution of 10 ms.

[0076] The determination of the roof-lifting height is made by extracting the maximum value S_max from the displacement data and comparing it with the preset height threshold S_set. If S_max ≥ S_set - allowable error (such as 5 mm), the height meets the standard; otherwise, mark "insufficient height", which may be due to overloading or low transmission efficiency of the load.

[0077] The determination of the roof-lifting speed is made by calculating the average speed v_avg = (S_max - S_start) / (t_end - t_start), and it is required that v_avg is within the preset speed range [v_min, v_max] (such as 5 - 10 mm / s); the real-time speed monitoring calculates the instantaneous speed v(t) = ΔS / Δt through adjacent displacement sampling points. If v(t) > v_max at any time, trigger an alarm of "too fast speed" (which may cause impact load); if v(t) < v_min, prompt "too slow speed" (which may indicate excessive mechanical resistance).

[0078] The determination of load stability is made by checking the force sensor curve F(t). The allowable normal fluctuation range is ±5%F_set. If there is continuous deviation or high-frequency oscillation, determine "load instability", which may be caused by insufficient stiffness of the simulated load mechanism or loose connection.

[0079] The automatic shutdown conditions include: when the roof-lifting mechanism reaches the maximum range of the displacement sensor, triggers the limit switch, or the controller determines an abnormality (such as overload timeout, speed overlimit), automatically send a shutdown instruction to cut off the power supply.

[0080] The human-machine interface displays "Test passed" or "Test failed" and marks the specific non-conforming items (such as "Height less than 20mm" or "Instantaneous speed exceeds limit by 15mm / s"); it generates a test report, including force-displacement curves, velocity-time curves, and a list of key parameters (measured values ​​and preset values), and supports PDF export or uploading to the quality management system; abnormal situations trigger audible and visual alarms, record the fault time point and sensor data, and facilitate subsequent fault reproduction and analysis.

[0081] In some embodiments, if the lifting mechanism meets the preset lifting requirements under the test load, the method further includes: sequentially controlling the value of the test load to increase according to a preset adjustment rule; after each increase of the test load, sequentially controlling the lifting mechanism to lift in the opposite direction of the preset direction until the lifting mechanism does not meet the preset lifting requirements, obtaining the value of the corresponding test load and determining it as the limit load of the lifting mechanism.

[0082] The test load is increased incrementally by the controller according to a preset pattern to verify the lifting capacity of the lifting mechanism with each increase in load until the mechanism can no longer meet the preset lifting requirements (such as insufficient lifting height or excessive speed). The load value at this point is the ultimate load. This embodiment is used to evaluate the maximum load-bearing capacity of the lifting mechanism and provides data support for designing safety redundancy and rated load calibration.

[0083] The incremental mode supports two modes by setting load increment rules through the controller's human-machine interface: linear increment: increments by a fixed step size (e.g., 100N each time), suitable for preliminary testing; proportional increment: increments by a percentage of the current load (e.g., 5% of the rated load each time), suitable for precise measurement of extreme loads.

[0084] Termination conditions are determined by a preset threshold for "not meeting preset lifting requirements", such as: lifting height < 80% of preset height; speed continuously below preset lower speed limit for more than 5 seconds during lifting process; force sensor detects overload protection signal (such as lifting mechanism motor current exceeding limit).

[0085] The cyclic testing process starts with an initial load (such as 0N or minimum test load), executes steps S101-S103 to complete the first test, and if it meets the requirements, it enters the load increment process.

[0086] The controller calculates the target load Fn+1=Fn+ΔF for the next stage based on the preset step size, sends the command to the simulated load mechanism, and repeats the closed-loop control of step S102 until the current load stabilizes.

[0087] After each roof-lifting test, if any of the following situations occur, it is determined as "not meeting the requirements" and the test is terminated: the actual roof-lifting height Sreal < Sset×0.9 (the preset height compliance rate is 90%); the average roof-lifting speed vavg < vmin (if it is lower than 70% of the designed speed, it indicates insufficient power); the roof-lifting mechanism gets stuck, makes abnormal noises, or the motor overheats and is protected (monitored by a temperature sensor).

[0088] The limit load record is used to record the current test load value Ffail when "not meeting the requirements" first appears, and combined with the previous qualified load Fpass, the limit load is calculated by linear interpolation (such as taking Flimit=(Fpass + Ffail) / 2) to improve the accuracy.

[0089] Overload protection is achieved by setting the upper limit of load increase (such as 1.5 times the rated load) to prevent damage to the mechanism; if it still does not fail when reaching the upper limit, it will automatically terminate and prompt "safety redundancy compliance". The process record generates load-height curves and load-speed curves, marks the test results of each load stage, and supports export as a CSV file for subsequent reference in finite element analysis or fatigue testing.

[0090] In some embodiments, the preset roof-lifting requirements at least include a preset roof-lifting speed and a preset roof-lifting height; to confirm whether the roof-lifting mechanism meets the preset roof-lifting requirements, it includes: confirming whether it meets the preset roof-lifting speed according to the real-time roof-lifting speed corresponding to the roof-lifting process of the roof-lifting mechanism; and confirming whether it meets the preset roof-lifting height according to the maximum roof-lifting height corresponding to the roof-lifting process of the roof-lifting mechanism.

[0091] By clearly defining that the preset roof-lifting requirements include two core indicators, namely the real-time roof-lifting speed and the maximum roof-lifting height, the controller verifies whether the two indicators meet the standards through the real-time data of the displacement sensor, forming a multi-dimensional performance evaluation system to avoid the one-sidedness of single-index testing.

[0092] Preset roof-lifting speed: It includes a speed lower limit vmin and a speed upper limit vmax, which are set according to the type of roof-lifting mechanism (such as for electric type: 5 - 15 mm / s, for hydraulic type: 3 - 10 mm / s) to ensure smooth operation without impact.

[0093] Preset roof-lifting height: The target height Sset is set according to the design requirements of the RV (such as 300 mm), and the allowable error range is (such as ±5 mm, considering the elastic deformation of the mechanism).

[0094] The displacement sensor collects the position S(t) of the connecting plate at a high frequency (such as 100 Hz), and the controller calculates the instantaneous speed v(t) at adjacent moments as v(t)=ΔtS(t)−S(t−Δt), where Δt can be taken as 0.01 s.

[0095] If v(t) > vmax at any time, it is determined that "the speed is too fast", which may be caused by insufficient load or too high power of the drive system; if v(t) < vmin and the duration exceeds 2 seconds, it is determined that "the speed is too slow", which may be caused by increased mechanical resistance or insufficient drive current.

[0096] Average speed assistance: Calculate the average speed of the whole journey vavg = (Smax - Sstart) / (tend - tstart), and require vmin ≤ vavg ≤ vmax to ensure that the overall operation efficiency meets the standard.

[0097] The verification logic for the maximum lifting height includes: end point capture: when the lifting mechanism stops moving (triggering the limit switch or the displacement sensor reaching the range), record the displacement value Smax at this time as the actual lifting height. If Smax ≥ Sset - δ (δ is the allowable negative error, such as 5mm), and S max ≤ Sset + δ (to prevent over-travel risk), then the height meets the standard; otherwise, mark "insufficient height" or "over-travel anomaly" according to the deviation direction.

[0098] Only when the real-time speed is within the threshold throughout the whole process and the maximum height meets the standard, it is determined that "it meets the preset lifting requirements"; if any index does not meet the standard, the unqualified items are clearly marked in the test report (such as "speed limit exceeded by 18mm / s", "height is only 280mm < 300mm"), and the possible failure reasons are associated (such as load application deviation, insufficient guide rail lubrication).

[0099] It should be noted that those skilled in the art can clearly understand that for the convenience and simplicity of description, the test method of the motorhome lifting mechanism and the specific working processes of each step described above can refer to the corresponding processes in the test device embodiment of the motorhome lifting mechanism described in the above embodiments, and will not be repeated here.

[0100] Please refer to Figure 6 , Figure 6 is a schematic block diagram of the structure of the controller provided by the embodiment of the present application. The controller includes a processor, a memory, and a network interface connected through a device bus. Among them, the memory may include a storage medium and an internal memory.

[0101] The storage medium can store an operating device and a computer program. The computer program includes program instructions, and when the program instructions are executed, the processor can execute any embodiment of the test method of the motorhome lifting mechanism.

[0102] The processor is used to provide computing and control capabilities to support the operation of the entire controller.

[0103] The internal memory provides an environment for the execution of computer programs in non-volatile storage media. When the computer program is executed by the processor, it enables the processor to execute any test device method for a RV pop-up mechanism.

[0104] This network interface is used for network communication, such as sending assigned tasks. Those skilled in the art will understand that... Figure 6 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the terminal to which the present application is applied. The specific controller may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0105] It should be understood that the processor can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. Among these, a general-purpose processor can be a microprocessor or any conventional processor.

[0106] In one embodiment, the processor is configured to run a computer program stored in memory to perform the following steps: Obtain the preset load parameters corresponding to the lifting mechanism; The simulated load mechanism is controlled to apply a constant test load to the lifting mechanism along a preset direction based on the preset load parameters and the load force value. Control the lifting mechanism to lift in the opposite direction of the preset direction to confirm whether the lifting mechanism meets the preset lifting requirements and complete the test of the lifting mechanism; In some embodiments, if the lifting mechanism meets the preset lifting requirements under the test load, the method further includes: sequentially controlling the value of the test load to increase according to a preset adjustment rule; after each increase of the test load, sequentially controlling the lifting mechanism to lift in the opposite direction of the preset direction until the lifting mechanism does not meet the preset lifting requirements, obtaining the value of the corresponding test load and determining it as the limit load of the lifting mechanism.

[0107] In some embodiments, the preset lifting requirements include at least a preset lifting speed and a preset lifting height; confirming whether the lifting mechanism meets the preset lifting requirements includes: confirming whether it meets the preset lifting speed based on the real-time lifting speed of the lifting mechanism during the lifting process; and confirming whether it meets the preset lifting height based on the maximum lifting height of the lifting mechanism during the lifting process.

[0108] It should be noted that those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the processor described above can be referred to the corresponding process in the method embodiments of the above embodiments, and will not be repeated here.

[0109] The embodiments of this application also provide a computer-readable storage medium storing a computer program, the computer program including program instructions, and the processor executing the program instructions to implement the steps of the testing method for the RV pop-up mechanism provided in the above embodiments of this application.

[0110] The computer-readable storage medium may be an internal storage unit of the controller as described in the foregoing embodiments, such as the hard disk or memory of the controller. Alternatively, the computer-readable storage medium may be an external storage device of the controller, such as a plug-in hard disk, Smart Media Card (SMC), Secure Digital (SD) card, or Flash Card.

[0111] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A testing device for a RV pop-up roof mechanism, characterized in that, The testing apparatus includes: The frame, and the lifting mechanism to be tested, is fixed inside the frame; A simulated load mechanism is connected to both the frame and the lifting mechanism. A force sensor is used to measure the load force transmitted from the simulated load mechanism to the lifting mechanism; The controller is configured to control the simulated load mechanism to apply a constant test load to the lifting mechanism along a preset direction based on preset load parameters and the load force value measured by the force sensor, and to control the lifting mechanism to lift in the opposite direction of the preset direction, so as to confirm whether the lifting mechanism meets the preset lifting requirements.

2. The testing apparatus according to claim 1, characterized in that, One end of the lifting mechanism is fixedly connected to the base plate of the frame; the testing device also includes: A connecting plate is provided, and the other end of the lifting mechanism is fixedly connected to the connecting plate. The simulated load mechanism is disposed above the connecting plate so that the simulated load mechanism applies the test load to the lifting mechanism through the connecting plate.

3. The testing apparatus according to claim 2, characterized in that, The testing apparatus also includes: The guide rail is fixed inside the frame, and the connecting plate is movably connected to the guide rail to control the lifting mechanism to move along the preset direction or the opposite direction of the preset direction.

4. The testing apparatus according to claim 2, characterized in that, The top plate of the frame has a through hole; the simulated load mechanism includes: The fixing part is fixed to the top plate through the through hole; The telescopic part has one end movably connected to the fixed part, and the other end of the telescopic part is connected to the connecting plate through the force sensor.

5. The testing apparatus according to claim 4, characterized in that, The testing apparatus also includes: A displacement sensor is used to measure the displacement of the lifting mechanism.

6. The testing apparatus according to claim 5, characterized in that, The preset lifting requirements include at least a preset lifting height requirement; the controller obtains the maximum lifting height of the lifting mechanism under the test load based on the displacement information measured by the displacement sensor, in order to determine whether it meets the preset lifting height requirement.

7. The testing apparatus according to claim 5, characterized in that, The preset lifting requirements include at least a preset lifting speed requirement; the controller obtains the real-time lifting speed of the lifting mechanism under the test load based on the displacement information measured by the displacement sensor, in order to confirm whether it meets the preset lifting speed requirement.

8. A test method for a RV pop-up roof mechanism, characterized in that, A controller for a test apparatus applied to the RV pop-up roof mechanism according to any one of claims 1-8, the method comprising: Obtain the preset load parameters corresponding to the lifting mechanism; The simulated load mechanism is controlled to apply a constant test load to the lifting mechanism along a preset direction based on the preset load parameters and the load force value. The lifting mechanism is controlled to lift in the opposite direction of the preset direction to confirm whether the lifting mechanism meets the preset lifting requirements and to complete the test of the lifting mechanism.

9. The method according to claim 8, characterized in that, If the lifting mechanism meets the preset lifting requirements under the test load, the method further includes: The value of the test load is sequentially increased according to a preset adjustment rule; After each increment of the test load, the lifting mechanism is sequentially controlled to lift in the opposite direction of the preset direction until the lifting mechanism no longer meets the preset lifting requirements. Then, the value of the corresponding test load is obtained and determined as the limit load of the lifting mechanism.

10. The method according to claim 8, characterized in that, The preset lifting requirements include at least a preset lifting speed and a preset lifting height; confirming whether the lifting mechanism meets the preset lifting requirements includes: Confirm whether the preset lifting speed is met based on the real-time lifting speed of the lifting mechanism during the lifting process; Based on the maximum lifting height of the lifting mechanism during the lifting process, confirm whether it conforms to the preset lifting height.

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