Shifting fork test method, system, device and computer program product

Abstract

The invention discloses a shifting fork testing method, system and device and a computer program product. The method comprises the steps that test item information of a gear shifting fork is obtained, the test item information at least comprises test environment temperature and test differential lock working conditions, and a differential lock and the gear shifting fork are located in the same transmission; the testing environment temperature of the gear shifting fork is adjusted to the testing environment temperature, and the differential lock is adjusted to the testing differential lock working condition; in response to the situation that the testing environment of the gear shifting fork is at the testing environment temperature and the differential lock is in the differential lock testing working condition, a gear shifting force loading test is executed, stress data of the gear shifting fork in the gear shifting force loading test process is monitored, and the gear shifting force loading test comprises the steps that a gear shifting force loading device is controlled to load gear shifting force to the gear shifting fork for preset duration; and generating a test result of the shifting fork based on the stress data, and determining whether the shifting fork is qualified or not based on the test result. According to the invention, the technical problem of poor testing accuracy of the shifting fork in the prior art is solved.

Description

Technical Field

[0001] This invention relates to the field of component performance testing technology, and more specifically, to a shift fork testing method, system, device, and computer program product. Background Technology

[0002] In the field of off-road vehicle differential locks, the shift fork, as a key transmission component, directly affects the reliability and lifespan of the differential lock due to its stress performance. Current technologies often employ single-condition simulation or static load testing to test the stress on shift forks. For example, some solutions only assess shift fork strength through theoretical calculations or simple bench tensile tests, failing to consider the complex dynamic conditions during actual shifting, such as gear engagement, smooth shifting, and disengagement. This leads to significant discrepancies between test results and real-world conditions, limiting the effectiveness and accuracy of the testing.

[0003] There is currently no effective solution to the above problems. Summary of the Invention

[0004] This invention provides a method, system, device, and computer program product for testing shift forks, to at least solve the technical problem of poor accuracy in shift fork testing in related technologies.

[0005] According to one aspect of the present invention, a method for testing a shift fork is provided. The method includes the following steps: acquiring test item information for the shift fork, the test item information including at least test ambient temperature and test differential lock operating conditions, wherein the differential lock and the shift fork are located within the same transmission; adjusting the test environment of the shift fork to the test ambient temperature and adjusting the differential lock to the test differential lock operating conditions; in response to the test environment of the shift fork being at the test ambient temperature and the differential lock being in the test differential lock operating conditions, performing a shift force loading test and monitoring the force data of the shift fork during the shift force loading test, wherein the shift force loading test includes controlling a shift force loading device to apply a shift force to the shift fork for a preset duration; generating a test result for the shift fork based on the force data, and determining whether the shift fork is qualified based on the test result.

[0006] Optionally, before monitoring the force data of the shift fork, the method further includes: attaching strain gauges to multiple target test areas of the shift fork, the strain gauges being used to collect strain data of the target test areas.

[0007] Optionally, the multiple target test areas include at least the fork area, the dial area, the upper side area of ​​the sleeve, and the lower side area of ​​the sleeve.

[0008] Optionally, the shift force loading test is a multi-item test, which includes: performing each shift force loading test separately, and repeating each shift force loading test a preset number of times; wherein the shift force of each shift force loading test is set differently.

[0009] Optionally, the shift force loading device includes an actuator motor. Before performing the shift force loading test, the method further includes: installing a standard force sensor at the output end of the actuator motor; starting the motor and recording the sensor reading of the standard force sensor and the motor display force value displayed by the motor control system, wherein the motor control system is electrically connected to the actuator motor; and calibrating the actuator motor based on the sensor reading and the motor display force value.

[0010] Optionally, the shift force loading rates of at least two shift force loading tests are set differently.

[0011] Optionally, the differential lock test conditions include at least one of the following: top gear condition, normal shifting condition, and unlocking condition.

[0012] According to another aspect of the present invention, a shift fork testing system is also provided, comprising: a temperature regulating device for regulating the ambient temperature of the testing environment; a strain detection device disposed on the shift fork for collecting strain data of the shift fork; a loading module including a shift force loading device and a differential lock loading device, the output end of the shift force loading device being connected to the shift fork, the shift force loading device being used to output a shift force, and the differential lock loading device being used to apply differential lock operating conditions; and a control device electrically connected to the temperature regulating device, the strain detection device, and the loading device.

[0013] Optionally, the strain detection device includes multiple strain gauges, all of which are attached to the shift fork.

[0014] According to another aspect of the present invention, a shift fork testing device is also provided, comprising: an acquisition module for acquiring test item information of the shift fork, the test item information including at least test ambient temperature and test differential lock operating condition, wherein the differential lock and the shift fork are located in the same transmission; an adjustment module for adjusting the test ambient temperature of the shift fork to the test ambient temperature and adjusting the differential lock to the test differential lock operating condition; an execution module for performing a shift force loading test in response to the test ambient temperature of the shift fork and the differential lock being in the test differential lock operating condition, and monitoring the force data of the shift fork during the shift force loading test; and a generation module for generating test results of the shift fork based on the force data, and determining whether the shift fork is qualified based on the test results.

[0015] According to another aspect of the present invention, a computer program product is also provided, including computer instructions that, when executed by a processor, implement the steps of the above-described method.

[0016] In this embodiment of the invention, test item information of the shift fork is obtained. The test item information includes at least the test ambient temperature and the test differential lock condition. The differential lock and the shift fork are located in the same transmission. The test ambient temperature of the shift fork is adjusted to the test ambient temperature, and the differential lock is adjusted to the test differential lock condition. In response to the test environment of the shift fork being at the test ambient temperature and the differential lock being in the test differential lock condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to apply a shift force to the shift fork for a preset duration. Based on the force data, the test result of the shift fork is generated, and the pass / fail status of the shift fork is determined based on the test result. By adjusting the test environment to the set temperature conditions and adjusting the differential lock to different working states, the environmental changes and load conditions of the shift fork in actual operation can be simulated. This allows the shift fork to undergo shifting force loading tests under simulated actual operating temperature and differential lock conditions. This makes the operating conditions of the shift fork during testing closer to actual operating conditions, resulting in more accurate test results. This solves the technical problem of poor accuracy in shift fork testing in related technologies. Based on more accurate test results, potential failure points, weak points, and areas to be optimized in the shift fork can be effectively identified, providing a reliable basis for the optimized design of the shift fork structure, thereby significantly improving the reliability and service life of the shift fork. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a hardware structure block diagram of a computer terminal for a shift fork testing method according to one embodiment of the present invention; Figure 2 This is a flowchart of a shift fork test method according to an optional embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of a shift fork according to one embodiment of the present invention; Figure 4 This is a schematic diagram of the test phase of a shift fork test method according to one embodiment of the present invention; Figure 5 This is a structural block diagram of a shift fork testing device according to one optional embodiment of the present invention.

[0018] The above figures include the following reference numerals: 1. Shift fork;

[0019] 11. Fork foot area; 12. Die head area; 13. Upper side area of ​​the sleeve; 14. Lower side area of ​​the sleeve. Detailed Implementation

[0020] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0021] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0022] According to one embodiment of the present invention, an embodiment of a shift fork testing method is provided. It should be noted that the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Furthermore, although a logical order is shown in the flowchart, in some cases, the steps shown or described may be executed in a different order than that shown here.

[0023] This method embodiment can be executed in a computer terminal or similar computing device that includes memory and a processor. Taking running on a computer terminal as an example, such as... Figure 1As shown, a computer terminal may include one or more processors 102 (processors may include, but are not limited to, central processing units (CPUs), graphics processing units (GPUs), digital signal processing (DSP) chips, microprocessors (MCUs), programmable logic devices (FPGAs), neural network processors (NPUs), tensor processors (TPUs), artificial intelligence (AI) type processors, etc.) and a memory 104 for storing data. Optionally, the computer terminal may also include a transmission device 106 for communication functions, an input / output device 108, and a display 110. Those skilled in the art will understand that... Figure 1 The structure shown is for illustrative purposes only and does not limit the structure of the computer terminal described above. For example, the computer terminal may include more or fewer components than those described above, or have a different configuration than those described above.

[0024] The memory 104 can be used to store computer programs, such as application software programs and modules, like the computer program corresponding to the shift fork test method in this embodiment of the invention. The processor 102 executes various functional applications and data processing by running the computer program stored in the memory 104, thereby realizing the aforementioned shift fork test method. The memory 104 may include high-speed random access memory, and may also include non-volatile memory, such as one or more magnetic storage devices, flash memory, or other non-volatile solid-state memory. In some instances, the memory 104 may further include memory remotely located relative to the processor 102, and these remote memories can be connected to a mobile terminal via a network. Examples of such networks include, but are not limited to, the Internet, corporate intranets, local area networks, mobile communication networks, and combinations thereof.

[0025] The transmission device 106 is used to receive or send data via a network. Specific examples of the network described above may include a wireless network provided by the mobile terminal's communication provider. In one example, the transmission device 106 includes a Network Interface Controller (NIC), which can connect to other network devices via a base station to communicate with the Internet. In another example, the transmission device 106 may be a Radio Frequency (RF) module used for wireless communication with the Internet.

[0026] Display 110 may be, for example, a touchscreen liquid crystal display (LCD). This LCD enables a user to interact with the user interface of the mobile terminal. In some embodiments, the mobile terminal has a graphical user interface (GUI), which allows the user to interact with the GUI via finger contact and / or gestures on a touch-sensitive surface. The human-computer interaction functions may optionally include: creating web pages, drawing, word processing, creating electronic documents, playing games, video conferencing, instant messaging, sending and receiving emails, a call interface, playing digital video, playing digital music, and / or web browsing, etc. Executable instructions for performing the aforementioned human-computer interaction functions are configured / stored in one or more processor-executable computer program products or readable storage media.

[0027] This embodiment provides a method for testing a shift fork running on the aforementioned computer terminal. Figure 2 This is a flowchart of a shift fork testing method according to one embodiment of the present invention, such as... Figure 2 As shown, the process includes the following steps: Step S21: Obtain test item information for the shift fork. The test item information includes at least the test ambient temperature and the test differential lock operating condition. The differential lock and the shift fork are located in the same transmission.

[0028] In step S21, the differential lock and shift fork are located within the same transmission. The operating condition of the differential lock directly affects the shifting operation of the shift fork. For example, when the differential lock is in the engaged position, the shift fork requires greater shifting force to shift smoothly, while when the differential lock is in the fully engaged position, the shift fork requires less shifting force. During testing, the transmission containing the shift fork can be placed directly on the vehicle, or it can be disassembled and placed on the test steps inside the environmental chamber, which can be used to regulate the test environment temperature.

[0029] Specifically, the test environment temperature can range from extremely cold -40℃ to extremely hot 120℃ to cover the temperature range that off-road vehicles may encounter; the test conditions for the differential lock may include normal shifting, gear shifting, disengaging, and specific conditions combined with the vehicle's driving status. Depending on the actual needs, multiple test items may be required when testing a shift fork, with different test item information for each item, thereby obtaining test data for the shift fork under various simulated operating conditions.

[0030] Step S22: Adjust the test environment of the shift fork to the test ambient temperature and adjust the differential lock to the test differential lock operating condition.

[0031] In step S22, temperature regulation can be achieved through the environmental chamber's own temperature regulation function or through an additional heating or cooling device. Differential lock adjustment can be achieved by sending commands to the differential lock actuator motor, for example, controlling the rotation direction and speed of the differential lock actuator motor to change the meshing of the differential lock gears, thereby simulating different differential lock operating conditions.

[0032] Step S23: In response to the test environment of the shift fork being at the test environment temperature and the differential lock being in the test differential lock working condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to load a shift force onto the shift fork and continuing for a preset duration.

[0033] Specifically, in step S23, the shift force loading test can be achieved by sending commands to the shift force loading motor, for example, controlling the motor's direction, speed, and torque output to obtain different shift forces. The loading process includes not only the application of force but also the duration of the loading, such as 10 seconds, to observe the dynamic response of the shift fork under the action of the shift force. The force data can include various types of data such as stress, strain, and displacement.

[0034] Step S24: Based on the force data, generate the test results of the shift fork, and determine whether the shift fork is qualified based on the test results.

[0035] Specifically, in step S24, the stress data can be analyzed in various ways to generate test results. For example, based on the collected stress data, data analysis can be performed to generate a detailed test report. The report includes the stress change curve of the shift fork under each test condition, the peak stress location, the stress-strain relationship, etc. Based on the test results, it can be determined whether the shift fork meets the design requirements, that is, whether it can maintain structural stability under all test conditions, not exceed the safe stress range, and not show obvious structural deformation or damage. When the shift fork meets the design requirements, it can be determined that the shift fork is qualified.

[0036] Through the above steps, the test item information of the shift fork is obtained. The test item information includes at least the test ambient temperature and the test differential lock condition. The differential lock and the shift fork are located in the same transmission. The test ambient temperature of the shift fork is adjusted to the test ambient temperature, and the differential lock is adjusted to the test differential lock condition. In response to the test ambient temperature of the shift fork and the differential lock being in the test differential lock condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to apply a shift force to the shift fork for a preset duration. Based on the force data, the test result of the shift fork is generated, and the pass / fail status of the shift fork is determined based on the test result. By adjusting the test environment to the set temperature conditions and adjusting the differential lock to different working states, the environmental changes and load conditions of the shift fork in actual operation can be simulated. This allows the shift fork to undergo shifting force loading tests under simulated actual operating temperature and differential lock conditions. This makes the operating conditions of the shift fork during testing closer to actual operating conditions, resulting in more accurate test results. This solves the technical problem of poor accuracy in shift fork testing in related technologies. Based on more accurate test results, potential failure points, weak points, and areas to be optimized in the shift fork can be effectively identified, providing a reliable basis for the optimized design of the shift fork structure, thereby significantly improving the reliability and service life of the shift fork.

[0037] Optionally, before monitoring the force data of the shift fork, the method further includes:

[0038] Step S25: Attach strain gauges to multiple target test areas of the shift fork. The strain gauges are used to collect strain data of the target test areas.

[0039] In this embodiment, before monitoring the force data of the shift fork, strain gauges are attached to multiple target test areas of the shift fork. The strain gauges can collect and convert the strain data of the target test areas into analyzable signals, enabling the testing system to directly measure the strain experienced by different parts of the shift fork under different test ambient temperatures and different differential lock operating conditions. The high sensitivity of the strain gauges ensures accurate capture of minute strains, providing a reliable basis for subsequent data analysis and structural optimization.

[0040] Optionally, the multiple target test areas include at least the fork area, the dial area, the upper side area of ​​the sleeve, and the lower side area of ​​the sleeve.

[0041] The fork foot area, shift head area, upper sleeve area, and lower sleeve area are stress concentration areas during the shift fork operation. By monitoring the strain of these stress concentration areas, the testing device can capture the stress changes of the shift fork under different working conditions, making the testing process more comprehensive and providing accurate data support for subsequent structural optimization.

[0042] Specifically, by setting up strain gauges for data acquisition in different stress concentration areas, it is also convenient to compare the strain values ​​of each area under different working conditions and temperature conditions, and to make targeted adjustments to the material selection, thickness distribution or geometry of the shift fork in each area, so as to enhance its reliability and fatigue resistance in practical applications.

[0043] In other embodiments, the arrangement and number of strain gauges can be adjusted according to specific testing requirements. For example, the number of strain gauges can be increased to improve testing accuracy, or their positions can be adjusted to more comprehensively assess the stress on the shift fork. More monitoring points can also be added as needed, such as strain monitoring of the connecting pin, shift groove, middle of the fork body, and base of the shift fork, to ensure the comprehensiveness of the test and the reliability of the data, more accurately analyze the stress on the entire shift mechanism, and further improve the effectiveness and relevance of the test.

[0044] like Figure 3 As shown, the fork foot area 11, shift head area 12, upper sleeve area 13, and lower sleeve area 14 of the shift fork 1 each contain one or more strain gauges. During actual operation, the fork foot area 11 contacts the gear during shifting and bears direct pushing load. Therefore, the strain data of this area can reflect the stress distribution of the shift fork at the moment of shifting. The shift head area 12 is the part where the shift fork connects to the differential lock. The shift head area 12 not only bears force during shifting but also plays the role of accurately transmitting shifting commands. Its stress condition directly affects the smoothness and reliability of shifting. The upper sleeve area 13 and lower sleeve area 14 play a supporting and guiding role in the shift fork structure. Since the upper and lower sleeves bear different load directions and magnitudes under different test differential lock conditions (such as top teeth, smooth engagement), monitoring the strain at these two locations helps to understand the structural response of the shift fork under complex stress conditions. By comparing and analyzing the strain data of each region under different test differential lock conditions and temperatures, the weak points of the shift fork can be accurately located, providing data support for subsequent structural optimization.

[0045] For example, in one specific embodiment, when the temperature is -40°C and the shifting force is 1200N, the strain value of the lower sleeve region 14 is significantly higher than that of the fork region 11 and other regions. This may indicate that under the combined effects of extreme low temperature and high shifting force, the lower sleeve region 14 may become a stress concentration point, posing a risk of structural failure. Targeted reinforcement can be applied to the lower sleeve structure of the shift fork, such as increasing the material thickness or selecting a higher strength material, to optimize the shift fork structure.

[0046] Optionally, the shift force loading test includes multiple steps. In step S23, the shift force loading test is performed, including:

[0047] Step S231: Perform each shift force loading test separately, and repeat each shift force loading test a preset number of times; wherein, the shift force for each shift force loading test is set differently.

[0048] In step S231, during the shift force loading test, repeated tests with different shift force loading values ​​are performed. Each shift force loading test has a specific loading force value and is repeated a preset number of times. This method comprehensively covers the impact of different shift forces from low to high on the shift fork, ensuring that the stress on the shift fork is accurately assessed under various operating forces. The differentiated shift force settings help identify the stress distribution characteristics of the shift fork under different force values, thereby discovering structural weaknesses. This multi-level, multi-repetition testing strategy improves the reliability of the test data and provides more detailed reference for subsequent structural optimization, enhancing the reliability and durability of the shift fork under extreme conditions.

[0049] In other embodiments, the force on the shift fork can be evaluated from multiple angles by adjusting the loading rate and direction of the shift force in different shift force loading tests, thereby further enhancing the comprehensiveness and effectiveness of the test.

[0050] Optionally, the shift force loading device includes an actuator motor, and before performing the shift force loading test, the method further includes: Step S261: Install the standard force sensor at the output end of the actuator motor; Step S262: Start the motor and record the sensor reading of the standard force sensor and the motor force value displayed by the motor control system, wherein the motor control system is electrically connected to the motor.

[0051] Step S263: Based on the sensor readings and the force value displayed by the motor, calibrate the actuator motor.

[0052] Through steps S261-S263, before performing the shift force loading test, a standard force sensor is installed at the output end of the actuator motor. By starting the motor and recording the reading of the standard force sensor and the force value displayed by the motor control system, the actuator motor is accurately calibrated, ensuring the control of the loading force error and providing high-precision test conditions. This allows subsequent shift force variable tests to more accurately simulate actual working conditions, thereby providing reliable data support for the multi-part coordinated force monitoring of the shift fork.

[0053] It should be noted that the loading force error determined by the reading of the standard force sensor and the force value displayed by the motor control system can be controlled to adjust the accuracy according to actual needs. Preferably, the loading force error is controlled within ±1%.

[0054] Optionally, the shift force loading rates of at least two shift force loading tests are set differently.

[0055] In this embodiment, by applying shifting forces at different loading rates to the shift fork, the impact load during rapid shifting and the continuous stress during slow shifting can be simulated. This allows for a more accurate identification of stress concentration areas and potential failure modes of the shift fork at different shifting speeds. Differentiated loading rates help reveal the stress state of the shift fork under high-speed and low-speed loading, enabling a more comprehensive evaluation of its performance under complex environmental conditions and providing more detailed data support for subsequent structural optimization and material selection.

[0056] Optionally, the differential lock test conditions include at least one of the following: top gear condition, normal shifting condition, and unlocking condition.

[0057] In this embodiment, during the simulation of the top gear operation, a high-speed load is applied to push the shift fork, causing the gear sleeve to impact. This allows for the examination and recording of the ultimate stress state of the shift fork under forced engagement, identifying potential stress concentrations or material failure points. During the simulation of normal shifting, a high-speed load is applied to push the shift fork, allowing for smooth gear sleeve engagement. This enables precise measurement of the stress distribution under normal operating conditions, evaluating the dynamic response and structural stability during shifting. During the simulation of unlocking, the motor is controlled to apply reverse load, simulating the differential lock unlocking process. This allows for the detection of stress changes in the shift fork under reverse force, ensuring its reliability and safety during unlocking operations. These tests of the shift fork under differential lock operating conditions comprehensively evaluate the shift fork's stress performance, providing comprehensive data support for subsequent structural optimization.

[0058] In other embodiments, various operating conditions can be further subdivided and simulated by combining parameters such as vehicle driving status (e.g., uphill, downhill, turning, etc.), load conditions (empty and fully loaded), and driving mode (economy mode, sport mode), so as to more accurately test the performance of the shift fork under complex driving conditions.

[0059] According to another embodiment of this application, a shift fork testing system is also provided, including a temperature regulating device, a strain detection device, a loading module, and a control device. The temperature regulating device is used to regulate the ambient temperature of the testing environment; the strain detection device is disposed on the shift fork and is used to collect strain data of the shift fork; the loading module includes a shift force loading device and a differential lock loading device, the output end of the shift force loading device is connected to the shift fork, the shift force loading device is used to output the shift force, and the differential lock loading device is used to load the differential lock working condition; the control device is electrically connected to the temperature regulating device, the strain detection device, and the loading device.

[0060] By applying the technical solution of this embodiment, a temperature control device can simulate the temperature changes of the shift fork's operating environment, a strain detection device can monitor and collect strain data of the shift fork at multiple locations in real time, and the shift force loading device and differential lock loading device in the loading module can apply shift force and simulate differential lock conditions as needed. The control device coordinates and manages the entire testing process to achieve strain monitoring of the shift fork under specific temperatures and different shift conditions. This system, through coupled testing of multiple variables, can more accurately reflect the stress situation of the shift fork in actual applications, thereby improving the comprehensiveness and accuracy of the test. It avoids evaluation deviations that may be caused by testing under a single operating condition or static load, and solves the problems of insufficient force testing and distorted operating condition simulation in existing technologies. By precisely controlling the shift force, ambient temperature, and simulating different operating conditions, the shift fork testing system of this embodiment can effectively identify the weak points of the shift fork, provide reasonable optimization design suggestions, and enhance the reliability and durability of the shift fork and its associated differential lock system.

[0061] Optionally, the strain detection device includes multiple strain gauges, all of which are attached to the shift fork.

[0062] In this embodiment, by attaching multiple strain gauges to key parts of the shift fork, such as stress concentration areas on the fork feet, the shift head, and the upper and lower sides of the sleeve, the strain detection device can monitor the strain of multiple parts of the shift fork in real time when it is subjected to different shifting forces, various temperature environments, and dynamic operating conditions such as top gear engagement, smooth entry, and disengagement. This covers various stress conditions of the shift fork in practical applications. Moreover, by combining the collected strain data with shifting force and temperature parameters, and using data analysis methods, the location with the highest strain peak can be accurately identified, i.e., the potential weak point of the shift fork structure. Therefore, the strain detection device can provide accurate data support for the structural optimization of the shift fork, facilitating the subsequent determination of targeted improvement measures, such as adjusting material thickness, enhancing local strength, or improving geometric design, significantly improving the reliability and durability of the shift fork.

[0063] This application also provides a preferred embodiment of a shift fork testing system and testing method.

[0064] Specifically, the shift fork testing system consists of a loading system, a temperature control unit, a strain monitoring module, and a data acquisition and analysis system. The loading system uses a calibrated actuator motor, which can precisely control the shifting force and loading rate. The temperature control unit simulates the ambient temperature range of -40℃ to 120℃ through a heating / cooling device. The strain monitoring module attaches high-precision strain gauges to the fork feet, shift head, and upper and lower sides of the sleeve of the shift fork to collect strain data of each part in real time. The data acquisition and analysis system synchronously records parameters such as shifting force, temperature, and strain, and analyzes the stress distribution under different working conditions through algorithms.

[0065] The shift fork test method mainly includes the following test contents: Motor thrust calibration: The thrust of the actuator motor is calibrated using a standard force sensor to ensure that the loading force error is controlled within ±1%. Strain gauge arrangement: such as Figure 3 As shown, strain gauges are attached to the stress concentration area 11 of the shift fork 1, the shift head area 12, the upper side area 13 of the sleeve, and the lower side area 14 of the sleeve, and temperature compensation treatment is performed. Multi-condition testing: Shift force variable test: Set 3-5 different shift forces (such as 400N, 800N, 1200N) to simulate normal shifting and extreme working conditions; Temperature variable test: Repeat the above shifting force test at temperatures of -40℃, 0℃, 25℃, 50℃, 80℃, and 120℃; Operating condition simulation: By controlling the rotation of the actual vehicle's motor at different angles, three operating conditions are simulated: top gear (forced engagement), smooth entry (normal engagement), and disengagement (unlocking).

[0066] Data analysis: Using finite element comparative analysis and statistical methods, the location of strain peaks under different working conditions is identified, and the weak area of ​​the shift fork is determined.

[0067] Through multivariate coupling testing, the testing method in this embodiment can simulate the complex operating conditions of off-road vehicle differential locks throughout their entire lifecycle. Real-time monitoring of multiple parts by strain gauges, combined with dynamic changes in temperature and force, can capture stress concentration phenomena that are difficult to detect using traditional testing methods. For example, under top-tooth conditions, the strain on the upper and lower sides of the bushing outer sleeve will significantly increase due to impact loads, while the embrittlement of the bushing material at low temperatures will lead to a sudden increase in local stress. At high temperatures, the different materials of the bushing and sleeve result in different deformations, making the bushing prone to detachment. Through in-depth data acquisition and analysis, these weak points can be accurately located, providing quantitative basis for optimizing the shift fork thickness distribution, improving the rounded corner transition design, or replacing materials, thereby effectively improving the structural strength and reliability of the shift fork.

[0068] Specifically, such as Figure 4 As shown, the shift fork testing method in this embodiment includes four stages: preparation stage, device setup stage, testing process stage, and data acquisition and analysis stage. The specific contents of each stage are as follows:

[0069] Preparation Phase: Establish the test platform. Select an off-road vehicle reducer assembly as the test object. Prepare a high-precision standard force sensor for motor thrust calibration, capable of accurately measuring minute force changes. Prepare multiple high-precision strain gauges with sensitivity coefficient errors controlled within ±0.5% to ensure accurate strain measurement. Simultaneously, prepare heating / cooling equipment, ensuring temperature control accuracy within ±1℃ to stably simulate different ambient temperatures.

[0070] Device Setup: Install the calibrated actuator motor onto the reducer assembly, ensuring precise alignment of the motor output shaft with the loading direction of the shift fork, with an error controlled within ±0.5mm. In the stress concentration areas of the shift fork legs, precisely adhere strain gauges using a specialized adhesive, ensuring a tight fit between the strain gauges and the fork legs surface, free of air bubbles and gaps. Similarly, adhere strain gauges to the upper and lower sides of the shift head and sleeve, meeting the same high-precision requirements. Connect the strain gauge signal lines to the data acquisition and analysis system, ensuring stable signal transmission without interference.

[0071] Testing process:

[0072] Motor thrust calibration: Install a standard force sensor at the output of the actuator motor, start the motor, and apply thrust at a slow loading rate. Stop loading when the force reaches 400N, 800N, and 1200N. Record the readings of the standard force sensor and the force values ​​displayed by the motor control system, compare the errors between the two, and repeat the calibration three times to ensure that the motor thrust error is controlled within ±1%.

[0073] Multi-condition testing:

[0074] Shift force variable test: Three sets of shift forces were set, namely 400N, 800N, and 1200N. During each test, the motor was rapidly applied to the shift fork with the set force value to simulate rapid shifting conditions. Each loading method was repeated 5 times.

[0075] Temperature variable test: The temperature control unit was set sequentially to -40℃, 0℃, 25℃, 50℃, 80℃, and 120℃. After each temperature stabilized for 30 minutes, the above-mentioned shift force variable test was performed to ensure that the effect of temperature on material performance was fully reflected.

[0076] Operating condition simulation: By controlling the rotation of the actual vehicle's motor at a certain angle, the top gear condition is simulated: high-speed loading pushes the shift lever to cause the gear sleeve to impact, simulating the top gear; smooth entry condition: high-speed loading pushes the shift lever to smoothly enter the gear sleeve, simulating normal shifting; unlocking condition: the motor is controlled to apply reverse loading, simulating the differential lock unlocking process. Each operating condition is tested 10 times.

[0077] Data Acquisition and Analysis: The data acquisition and analysis system collects strain data, motor loading force values, and temperature data from strain gauges in real time at a frequency of 100Hz. After testing, the acquired data is compared with the simulation model using finite element analysis software. For example, under the top gear condition and at 80℃, data analysis revealed that the strain value at the outer sleeve of the shift fork bushing reached 800με, far exceeding other parts, identifying this location as a weak area. Based on this analysis, the shift fork structure was optimized, such as increasing the sleeve thickness from 5mm to 10mm to improve the stress concentration resistance of this area. The optimized shift fork was remanufactured and tested, and the results showed that the strain value at this location decreased to 500με, verifying the effectiveness of the structural optimization.

[0078] The testing system in this embodiment adopts an overall device structure and component combination method that includes a loading system (calibrating the actuator motor), a temperature control unit (heating / cooling device), a strain monitoring module (strain gauges are attached to specific locations), and a data acquisition and analysis system. This combination method is the hardware foundation for realizing multivariable coupled testing, multi-part collaborative monitoring, and accurate working condition simulation.

[0079] The test method and parameter setting process in this embodiment includes the motor thrust calibration process, strain gauge arrangement position and method, specific force value setting in shift force variable test (such as 400N, 800N, 1200N, etc.), specific temperature point setting in temperature variable test (-40℃, 0℃, 25℃, 50℃, 80℃, 120℃, etc.), as well as specific control method and data analysis method for working condition simulation, etc. These methods and parameter settings are the core operation steps of the test scheme in this embodiment.

[0080] The testing system and method in this embodiment, by constructing a multivariable coupled testing system, realize the coordinated stress monitoring of multiple parts of the shift fork under different shifting forces, temperatures and operating conditions (top teeth, smooth entry, unlocking, etc.), accurately identify the weak position with the greatest strain, and provide data support for the improvement of the shift fork structure. It can solve the problems of incomplete stress testing of shift forks, distorted operating condition simulation and inaccurate weak position location in the prior art.

[0081] The testing system and testing method in this embodiment have the following beneficial effects: 1) Comprehensive testing: The test comprehensively considers multiple factors such as shifting force, temperature, and dynamic operating conditions, covering key parts of the shift fork, and the test results are closer to the actual operating conditions. 2) Precisely locate weak points: Through multi-part strain monitoring and data analysis, quickly identify the areas of the shift fork prone to failure, shortening the structural optimization cycle;

[0082] 3) Improve design reliability: Optimize the shift fork structure based on test data, which can significantly improve the fatigue resistance and service life of the differential lock and reduce the risk of failure of off-road vehicles under complex road conditions.

[0083] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods according to the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk) and includes several instructions to cause a terminal device (which may be a mobile phone, computer, server, or network device, etc.) to execute the methods described in the various embodiments of the present invention.

[0084] This embodiment also provides a shift fork testing device, which is used to implement the above embodiments and preferred embodiments; details already described will not be repeated. As used below, the term "module" can refer to a combination of software and / or hardware that performs a predetermined function. Although the device described in the following embodiments is preferably implemented in software, hardware implementation, or a combination of software and hardware, is also possible and contemplated.

[0085] Figure 5 This is a structural block diagram of a shift fork testing device according to one embodiment of the present invention, such as... Figure 5 As shown, the device includes: an acquisition module 50, used to acquire test item information of the shift fork, the test item information including at least the test ambient temperature and the test differential lock condition, wherein the differential lock and the shift fork are located in the same transmission; an adjustment module 52, used to adjust the test ambient temperature of the shift fork to the test ambient temperature and adjust the differential lock to the test differential lock condition; an execution module 54, used to execute a shift force loading test in response to the shift fork being at the test ambient temperature and the differential lock being in the test differential lock condition, and to monitor the force data of the shift fork during the shift force loading test; and a generation module 56, used to generate test results for the shift fork based on the force data, and to determine whether the shift fork is qualified based on the test results.

[0086] Using the aforementioned device, test item information for the shift fork is acquired. This information includes at least the test ambient temperature and the test differential lock operating condition. The differential lock and shift fork are located within the same transmission. The test ambient temperature for the shift fork is adjusted to the test ambient temperature, and the differential lock is adjusted to the test differential lock operating condition. In response to the shift fork being at the test ambient temperature and the differential lock being in the test differential lock operating condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to apply a shift force to the shift fork for a preset duration. Based on the force data, test results for the shift fork are generated, and the pass / fail status of the shift fork is determined based on the test results. By adjusting the test environment to the set temperature conditions and adjusting the differential lock to different working states, the environmental changes and load conditions of the shift fork in actual operation can be simulated. This allows the shift fork to undergo shifting force loading tests under simulated actual operating temperature and differential lock conditions. This makes the operating conditions of the shift fork during testing closer to actual operating conditions, resulting in more accurate test results. This solves the technical problem of poor accuracy in shift fork testing in related technologies. Based on more accurate test results, potential failure points, weak points, and areas to be optimized in the shift fork can be effectively identified, providing a reliable basis for the optimized design of the shift fork structure, thereby significantly improving the reliability and service life of the shift fork.

[0087] It should be noted that the above modules can be implemented by software or hardware. For the latter, they can be implemented in the following ways, but are not limited to: all the above modules are located in the same processor; or, the above modules are located in different processors in any combination.

[0088] Embodiments of the present invention also provide a computer program that, when executed by a processor, implements the steps of the methods in the various embodiments of the present application.

[0089] Optionally, in this embodiment, the computer program described above is used to perform the following steps: Step S1: Obtain the test item information of the shift fork. The test item information includes at least the test ambient temperature and the test differential lock operating conditions. The differential lock and the shift fork are located in the same transmission. Step S2: Adjust the test ambient temperature of the shift fork to the test ambient temperature and adjust the differential lock to the test differential lock operating condition. Step S3: In response to the test environment of the shift fork being at the test ambient temperature and the differential lock being in the test differential lock working condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to apply a shift force to the shift fork and continuing for a preset duration.

[0090] Step S4: Based on the force data, generate the test results of the shift fork, and determine whether the shift fork is qualified based on the test results.

[0091] Embodiments of the present invention also provide a computer program product, including a non-volatile computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the methods in various embodiments of the present application.

[0092] Optionally, in this embodiment, the storage medium may be configured to store a computer program for performing the following steps: Step S1: Obtain the test item information of the shift fork. The test item information includes at least the test ambient temperature and the test differential lock operating conditions. The differential lock and the shift fork are located in the same transmission. Step S2: Adjust the test ambient temperature of the shift fork to the test ambient temperature and adjust the differential lock to the test differential lock operating condition. Step S3: In response to the test environment of the shift fork being at the test ambient temperature and the differential lock being in the test differential lock working condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to apply a shift force to the shift fork and continuing for a preset duration.

[0093] Step S4: Based on the force data, generate the test results of the shift fork, and determine whether the shift fork is qualified based on the test results.

[0094] Embodiments of the present invention also provide a storage medium storing a computer program, wherein the computer program is configured to execute the steps in any of the above method embodiments when running.

[0095] Optionally, in this embodiment, the storage medium may be configured to store a computer program for performing the following steps: Step S1: Obtain the test item information of the shift fork. The test item information includes at least the test ambient temperature and the test differential lock operating conditions. The differential lock and the shift fork are located in the same transmission. Step S2: Adjust the test ambient temperature of the shift fork to the test ambient temperature and adjust the differential lock to the test differential lock operating condition. Step S3: In response to the test environment of the shift fork being at the test ambient temperature and the differential lock being in the test differential lock working condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to apply a shift force to the shift fork and continuing for a preset duration.

[0096] Step S4: Based on the force data, generate the test results of the shift fork, and determine whether the shift fork is qualified based on the test results.

[0097] Optionally, in this embodiment, the storage medium may include, but is not limited to, various media capable of storing computer programs, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0098] Embodiments of the present invention also provide a processor configured to run a computer program to perform the steps in any of the above method embodiments.

[0099] Optionally, in this embodiment, the processor can be configured to perform the following steps via a computer program: Step S1: Obtain the test item information of the shift fork. The test item information includes at least the test ambient temperature and the test differential lock operating conditions. The differential lock and the shift fork are located in the same transmission. Step S2: Adjust the test ambient temperature of the shift fork to the test ambient temperature and adjust the differential lock to the test differential lock operating condition. Step S3: In response to the test environment of the shift fork being at the test ambient temperature and the differential lock being in the test differential lock working condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to apply a shift force to the shift fork and continuing for a preset duration.

[0100] Step S4: Based on the force data, generate the test results of the shift fork, and determine whether the shift fork is qualified based on the test results.

[0101] In the above embodiments of the present invention, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0102] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. The device embodiments described above are merely illustrative; for example, the division of units can be a logical functional division, and in actual implementation, there may be other division methods. For instance, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual coupling, direct coupling, or communication connection may be through some interfaces; the indirect coupling or communication connection between units or modules may be electrical or other forms.

[0103] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0104] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0105] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0106] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for testing a shift fork, characterized in that, The method includes the following steps: Obtain test item information for the shift fork, the test item information including at least the test ambient temperature and the test differential lock operating conditions, wherein the differential lock and the shift fork are located in the same transmission; The test environment for the shift fork is adjusted to the test environment temperature, and the differential lock is adjusted to the test differential lock operating condition; In response to the test environment of the shift fork being at the test environment temperature and the differential lock being in the test differential lock working condition, a shift force loading test is performed, and the force data of the shift fork during the shift force loading test is monitored. The shift force loading test includes controlling the shift force loading device to load a shift force onto the shift fork for a preset duration. Based on the force data, test results for the shift fork are generated, and the pass / fail status of the shift fork is determined based on the test results.

2. The method according to claim 1, characterized in that, Before monitoring the force data of the shift fork, the method further includes: Strain gauges are attached to multiple target test areas of the shift fork, and the strain gauges are used to collect strain data of the target test areas.

3. The method according to claim 2, characterized in that, The multiple target test areas include at least the fork area, the dial area, the upper side area of ​​the sleeve, and the lower side area of ​​the sleeve.

4. The method according to claim 1, characterized in that, The shift force loading test consists of multiple parts, including: Perform each of the shift force loading tests described herein, and repeat each of the shift force loading tests a preset number of times; The shifting force for each of the shifting force loading tests is set differently.

5. The method according to claim 1, characterized in that, The shift force loading device includes an actuator motor. Before performing the shift force loading test, the method further includes: Install a standard force sensor at the output end of the actuator motor; Start the motor and record the sensor reading of the standard force sensor and the motor force value displayed by the motor control system, wherein the motor control system is electrically connected to the actuator motor; The actuator motor is calibrated based on the sensor readings and the force value displayed by the motor.

6. The method according to claim 4, characterized in that, The shift force loading rates of at least two of the shift force loading tests are set differently.

7. The method according to claim 1, characterized in that, The test differential lock operating conditions include at least one of the following: top gear condition, normal shifting condition, and unlocking condition.

8. A shift fork testing system, characterized in that, include: A temperature regulating device, wherein the temperature regulating device is used to regulate the ambient temperature of the test environment; A strain detection device is disposed on the shift fork and is used to collect strain data of the shift fork. The loading module includes a shift force loading device and a differential lock loading device. The output end of the shift force loading device is connected to the shift fork. The shift force loading device is used to output shift force. The differential lock loading device is used to load the differential lock working condition. A control device is electrically connected to the temperature regulating device, the strain detection device, and the loading device.

9. The shift fork testing system according to claim 8, characterized in that, The strain detection device includes multiple strain gauges, all of which are attached to the shift fork.

10. A gear shift fork testing device, characterized in that, include: The acquisition module is used to acquire test item information of the shift fork. The test item information includes at least the test environment temperature and the test differential lock operating conditions, wherein the differential lock and the shift fork are located in the same transmission. An adjustment module is used to adjust the test environment temperature of the shift fork to the test environment temperature and the differential lock to the test differential lock operating condition. An execution module is configured to perform a shift force loading test in response to the test environment of the shift fork being at the test environment temperature and the differential lock being in the test differential lock operating condition, and to monitor the force data of the shift fork during the shift force loading test. A generation module is used to generate test results for the shift fork based on the force data, and to determine whether the shift fork is qualified based on the test results.

11. A computer program product comprising computer instructions, characterized in that, When the computer instructions are executed by the processor, they implement the steps of the method according to any one of claims 1-7.

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